Author Topic: 75' KZ400 Tracker/Enduro: Near Completion  (Read 6807 times)

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #10 on: Aug 22, 2016, 22:20:57 »
Some more parts arrived...

Headlight, grips, handlebars, mufflers, tubes, directionals, mirrors, lights and some other odds and ends.

I was able to get the rear fender chopped and fit better with the tail light installed. I'm a little iffy on the tail light placement, we'll see once I start piecing things together for the plate mount. I may end up going with a funky little integrated LED setup I found.

« Last Edit: May 10, 2017, 12:46:31 by DannyMotor »

Offline advCo

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  • Nick Ol' Eye
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Re: 75' KZ400
« Reply #11 on: Aug 22, 2016, 22:40:08 »
The wrinkle looks nice - what brand paint did you use for that?

Is that a Kz400 seat? I picked one up that looks almost exactly the same from a salvage yard not too long ago, but I have no idea what its from, except that its a Kawasaki.
"He broke the mirrors off his Cadillac, 'cause he doesn't like it looking like he looks back."

74 CB360 - Luna -
82 GS550L - Tracker-ish - - Sold
74 XL350 - The Turd -
Suzuki FA50 "No-Ped" -
73 Suzuki RV125 -

Offline AimlessMoto

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Re: 75' KZ400
« Reply #12 on: Aug 23, 2016, 14:44:26 »
Yup, that's the stock KZ400D seat, I think the S had a strap across it.

I used VHT Super Wrinkle or Wrinkle Plus (can't remember)... but you have to do three medium coats and wait 5 minutes between coats... if you put it on too thin or let it dry too fast it won't wrinkle up.

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #13 on: Aug 25, 2016, 18:07:52 »
Quick little, picture-less update.

I got all of the electrics run, built-up the upper triple, gauges, bars, switch gear, grips, bar end mirrors... the whole kit.

I then started to push through on the electrics. The only things I had to fabricate were a ground-strap, starter lead to the solenoid, and shorten up the hot wire to the battery. Other than that the entire harness is stock, with the exception of swapping connector ends for the tail light and directional...

The directionals were another fun project... I bought an LED flasher relay, which is controllable for blink speed... it works really great, but unfortunately when I plugged everything in and ran it as it was, all 4 blinkers were blinking regardless of left/right switch placement. I also found that I had a bad ground on my horn button.

A little bit of tinkering and I realized the blinkers were grounding out through the incandescent indicator light. Quick fix with a couple of resistors. As for the horn, it just needed the tab adjusted to touch the housing... now I get a full 12v to the horn harness when pushing the button.

We're close!

I'm actually hoping to get the bike outside, get it into a rolling chassis, and possibly get it started this weekend.

I also got around to wrapping the down-tubes for the exhaust. Just have to polish up the clamp rings, which should be done tonight. More pictures tomorrow!

My list is slowly going down.

Left to do:
- Check the valve clearance
- Check the timing
- Gap the points
- Gap the plugs
- Petcock
- Gas cap seal
- Check/torque all engine and mounting bolts to the frame
- Install exhaust, and drill new mounts for the mufflers.
- Get longer bolts for the clutch cover
- Install the front forks
- Get bolts for the front fender
- Install the wheels
- Install all the cables
- Install top tree with bars
- Install seat-pins
- Fabricate a license plate bracket
- Finish wiring the tail section

About 2 days worth of work if I take my time. :)

Offline AimlessMoto

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Re: 75' KZ400
« Reply #14 on: Aug 29, 2016, 03:28:38 »
Quick little update:

« Last Edit: May 10, 2017, 12:48:31 by DannyMotor »

Offline NoRiders

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Re: 75' KZ400
« Reply #15 on: Aug 29, 2016, 08:51:02 »
Coming together nicely, great project and liking the overall style you're going for.  Rear light reminds me of a 'trout pout' haha.

I've read those cheap Chinese shocks need rebuilding to work correctly....only read it mind, not had direct experience. Look great the gold accents.

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #16 on: Aug 29, 2016, 14:18:22 »
Those shocks are hit-and-miss. These ones seem to be in good working order. A friend of mine is running them on an XJ750 and they work really well on his application.

Here's a little video of the frame work and battery box.

Offline canyoncarver

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  • 'hacking is learning'
Re: 75' KZ400
« Reply #17 on: Aug 29, 2016, 14:35:38 »
Very nice.

YZF750/1000R The Fly
KZ 750 Twin
ZRX 1100
KZ400 The Rabbit
65 Norton, My damn Shovelhead chop, and an 86' FXR
more YZF750R's, the KZ's, a Zephyr750...and the unfinished 75' CB550 cafe.

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #18 on: Aug 30, 2016, 22:23:14 »
As of right now I can fully assemble the bike! I cleaned up all the over-spray from my rims and gave them a good scrub with some mother's and 00 steel wool. Finalized the exhaust, just need to clean it really well before first fire-up. Lubed all the cables, polished up the last bits like the shifter and exhaust clamps. Then installed my new petcock and got the whole kit-and-caboodle outside for assembly.

Forks are on, all the electrics are done, and I got the switch-gear all mounted. I may have to re-work my rear turn signal mounts, not sure if I like them mounted to the upper shock mounts. I think just painting the brackets will help a lot.

But EVERYTHING works! All the lights, and the starter! Hopefully one more weekend and I can try to start it!
« Last Edit: May 10, 2017, 12:49:24 by DannyMotor »

Offline AimlessMoto

  • Posts: 156
  • Blood, sweat and beers.
Re: 75' KZ400
« Reply #19 on: Sep 01, 2016, 17:44:19 »
I encountered a small hiccup...

The front drum brake refuses to be adjusted correctly, I either run out of cable, or can only get the front or rear pad to grab, and the lever will pull all the way back to the bars.

On closer inspection, it looks as though I installed the levers on the cam's a couple of teeth off... the pitch of the connecting rod is a tell-tale.

Should be a quick fix... but after that, I can finally fill the thing with oil and do a proper inspection of the valves and timing.