76 KZ400 Cafe

[mudchicken]

Well here are some pics. It was pretty crazy, something as simple as bolting on some clubmans turned into me tearing the whole front end off. Had to flip the head light ears to get the light lower. Only thing left to do is dremel the bucket to clear the brake line block. I wanna do something with the gauges to lower them as well. Anyone have any ideas on what to do about the cables and brake hose? I have too much of each now. The clutch will give me a work out in its current state, so I have to do something. Gonna play around with the routings but not sure I will be able to fix the issue. Also do I have the bars mounted right? I feel really comfortable on it, but a buddy is telling me I have them all wrong....I keep telling him this is my build and if he wants to build a bike he should build his own. But I also dont want to look like a clown either....(no comments) Thanks!

On another note I have the gas tank all clean and ready for the Honda petcock I have on order. Need that and then fuel goes in.

 

[mudchicken]

oh yeah clean tank...

and the current state of the bike today....

 

[reelinfeele]

I used red kote tank liner. Works great. I had to buy a petcock for a 69 cb750 to get the parts to rebuild the petcock. I tried just using the cb petcock but it didnt flow right. Kztwins is definetly the best place for info. They have saved me a butt load of time and money. The bars look right to me, whatever is comfortable. I ditched my clubmans for a set of renthals, they were very uncomfortable. The bikes are great, easy to work on. Some parts are difficult to locate, but kaw was famous for using the same parts on multiple bikes for years. Good luck!

 

[diggerdanh]

I have the same year and model as you so I can tell you what I did with the gauges. Since you flipped your headlight mounts upside down you can mount the gauge cluster a couple of inches lower using the existing parts. I see you already have the stock covers off so you're already ahead of the game! Basically just cut and drill out studs from the bottom half of the cover, find a couple of bolts that are a couple of inches long (long enough to pass through the top triple tree and rubber dampers, and then use them to mount the cluster underneath the top triple tree instead of on top where it used to be. You can still use the top cover, you'll have to cut off the two "ears" on the bottom-left and bottom-right so that the new trimmed piece will fit down in between the two mounts. You can use the existing rubber dampers (or additional ones) as spacers between the bottom of the triple tree and the cluster to "push" it down lower.

I know that probably doesn't make a lot of sense but if you look at your stock cluster and covers you'll figure it out. Let me know if you need additional info and I'll try to take some pics.

These should help visualize it:

You ought to be able to trim the top cover a little better than I did

 

[mudchicken]

I have the same year and model as you so I can tell you what I did with the gauges. Since you flipped your headlight mounts upside down you can mount the gauge cluster a couple of inches lower using the existing parts. I see you already have the stock covers off so you're already ahead of the game! Basically just cut and drill out studs from the bottom half of the cover, find a couple of bolts that are a couple of inches long (long enough to pass through the top triple tree and rubber dampers, and then use them to mount the cluster underneath the top triple tree instead of on top where it used to be. You can still use the top cover, you'll have to cut off the two "ears" on the bottom-left and bottom-right so that the new trimmed piece will fit down in between the two mounts. You can use the existing rubber dampers (or additional ones) as spacers between the bottom of the triple tree and the cluster to "push" it down lower.

I know that probably doesn't make a lot of sense but if you look at your stock cluster and covers you'll figure it out. Let me know if you need additional info and I'll try to take some pics.

These should help visualize it:

You ought to be able to trim the top cover a little better than I did

Ha! Thats what I was already thinking about doing. I was going to look into fliping the gauge plate and running the studs up from the bottom. I dont know if that will work but I wont take any gauge bracket grinding or cutting. Im not sure it will work yet but I hope to tear into it Saturday. Thanks for the pictures it allows me to see what im gonna do before I do it. I didnt even think about the guage cover needing to be cut. At least now I know I have to do that. Thanks!!

 

[mudchicken]

I have another issue that I am confused with. My brake/tail light doesnt work. The brake light in the guages is flashing all the time. It doesnt stop when any brakes are applied. I pulled the bulb and its fine. Im thinking this could be a bad ground but electrical is SO not my thing. Anyone know how to check this or troubleshoot it?

 

[mudchicken]

Well I got my new used carbs in the mail today so I spent some time cleaning them. Just have to put them back on the bike now. I mounted my clubmans and with this I wanted to lower the light. So I flipped the ears and lowered it. I then had to cut the bucket out to clear the brake line junction. All I have to do now is drill the bars for the throttle and try to route the cables better. I wanna lower the gauges so for the time being I pulled all that apart and mounted the bracket upside down. All I have to do to that now is trim the idiot light bezel. Tomorrow I want to mount the carbs and route some cables. I think I will try to get her running then. Keep your fingers crossed for me and wish me luck!

Oh yeah can anyone tell me what the little thing in the last picture is? Its mounted to the front right fork. I did look around but all I found was an alarm... ??? Hell I didnt know KZ's had alarms...anyone have any ideas what it is?

 

[diggerdanh]

I answered this question on the Kawasaki Twins Owner Forum, but for those following along I'll answer here as well. That is a turn signal alarm that cam on the some of the early model KZ400s. I'm not sure which models and what years. Mine is a 76 KZ400 D3 and I had one. If it works and everything is wired up properly you'll get a pretty loud buzzing sound when your turn signals are on. You'll probably want to disconnect and remove it

 

[mudchicken]

I answered this question on the Kawasaki Twins Owner Forum, but for those following along I'll answer here as well. That is a turn signal alarm that cam on the some of the early model KZ400s. I'm not sure which models and what years. Mine is a 76 KZ400 D3 and I had one. If it works and everything is wired up properly you'll get a pretty loud buzzing sound when your turn signals are on. You'll probably want to disconnect and remove it

Thanks! It will be removed right away. ;D

 

[mudchicken]

Well bars are mounted rear fender and signals are gone. Hope to get some time to throw the carbs on and try to get her started.

 

[mudchicken]

Well carbs are all clean and in place, I modified the gauge bracket to lower it. Now the tops of the gauges are almost in line with the triple clamps. I had her running for a few seconds the other day but didnt like the issue I was having with the rectifier. I went to solder the wires to the rectifier and as I was removing the old electrical tape from the hack job the PO had done on the rectifier I broke a tab off. So now I have no rectifier. I went on ebay and ordered me up a non stock brand new rectifier for 4.99 shipped. I got two right away... ??? . I also put the new turn signals on and started to figure out how Im going to do the brake/tail light. I have a seat on order from Vietnam so that should be hear in a few more weeks. I had it custom made to have a nice thin seating area with a speed hump after. I have my fingers crossed that this thing turns out nice. So I just ran all the numbers for everything I have into her and Im looking at $652.33 cost of the bike $350 transfer title $100 So a grand total of $1102.33. I may go over budget a little due to tires and I may add some paint as well but I should still be around the $1500.00 mark and thats not to bad in my opinion for a neat little scoot.

 

[diggerdanh]

I look forward to seeing your new seat and hearing your feedback since I've been looking at them for a couple of months now. Looking good. I'm right in the same ballpark as far as initial cost and what I've put into it so far. If I end up doing the things that I want to do, new seat and new shocks, then I'll finish up around $1500 too. Being my first bike I learned some lessons though and I probably could have shaved a few more dollars off that - maybe closer to $1200-1300. There were some things that I bought/ordered that I didn't really need (things like carb kits, wheel bearings, ordered some things from Ebay that I could have gotten elsewhere - like Z1 enterprises). Not too bad though since I've seen a couple of nice cafe'd KZ400s sell in the $1500-$1900 range on Ebay recently.

 

[Shermanator86]

Looking good

 

[MILLENNIUM FALCON]

This is off topic but, I never noticed that you live about a hour and half from me........small world.

Well carbs are all clean and in place, I modified the gauge bracket to lower it. Now the tops of the gauges are almost in line with the triple clamps. I had her running for a few seconds the other day but didnt like the issue I was having with the rectifier. I went to solder the wires to the rectifier and as I was removing the old electrical tape from the hack job the PO had done on the rectifier I broke a tab off. So now I have no rectifier. I went on ebay and ordered me up a non stock brand new rectifier for 4.99 shipped. I got two right away... ??? . I also put the new turn signals on and started to figure out how Im going to do the brake/tail light. I have a seat on order from Vietnam so that should be hear in a few more weeks. I had it custom made to have a nice thin seating area with a speed hump after. I have my fingers crossed that this thing turns out nice. So I just ran all the numbers for everything I have into her and Im looking at $652.33 cost of the bike $350 transfer title $100 So a grand total of $1102.33. I may go over budget a little due to tires and I may add some paint as well but I should still be around the $1500.00 mark and thats not to bad in my opinion for a neat little scoot.

 

[mudchicken]

I look forward to seeing your new seat and hearing your feedback since I've been looking at them for a couple of months now. Looking good. I'm right in the same ballpark as far as initial cost and what I've put into it so far. If I end up doing the things that I want to do, new seat and new shocks, then I'll finish up around $1500 too. Being my first bike I learned some lessons though and I probably could have shaved a few more dollars off that - maybe closer to $1200-1300. There were some things that I bought/ordered that I didn't really need (things like carb kits, wheel bearings, ordered some things from Ebay that I could have gotten elsewhere - like Z1 enterprises). Not too bad though since I've seen a couple of nice cafe'd KZ400s sell in the $1500-$1900 range on Ebay recently.

Yeah I am the same, this is my second build. My first was a 72 Yamaha XS650 Bobber. It was a lil different since this bike is in a little better shape then my XS was. But hell even $1500 for a cool lil scoot isnt bad at all. 8)

 

[mudchicken]

This is off topic but, I never noticed that you live about a hour and half from me........small world.

Yes sir! We need to get together this year and take a ride.

 

[MILLENNIUM FALCON]

Yeah we will. Now if only it would warm up! :-[

Yes sir! We need to get together this year and take a ride.

 

[mudchicken]

Okay, Im having issues choosing tires for her. Not sure if I want to go old school or new school. Here is what I found, whats everyone think?

New School:
http://www.bikebandit.com/duro-hf918-motorcycle-tire

Old School:
Rear
http://www.bikebandit.com/dunlop-k70-vintage-motorcycle-tire

Front
http://www.bikebandit.com/duro-hf317-classic-vintage-motorcycle-tire

Let me know what ya's think, Im torn between both. :-\

 

[mudchicken]

Yeah we will. Now if only it would warm up! :-[

Yeah but its been a fairly mild winter so far. Lets keep our fingers crossed for an early spring! And hope the weather from today and tonight leaves real soon.....damn its just nasty out.

 

[MILLENNIUM FALCON]

I went modern (avon am26) and I haven't regretted it once. As long as you keep them on the skinny side I think they still look old school. It all depends on your riding style in the end.