KZ 400 Kawakazi Almost Finished!!!

Re: KZ 400 Kawakazi Build

Thanks for all the input Guys,
This gives me an idea of all the other options i have. I still want to keep the Ninja master cylinder and see if i can make it work somehow. I will definitely invest in one of those brake bleeding pumps and i also ordered a straight brake line, the curent one has a connector in the middle that i dont really know what it does. I also looked at the ratio chart and it looks like it will require a bigger MC with a bigger bore to work with the stock calipers. Also i just found out that small bore master cylinders push less volume than larger bores but they have a higher pressure ratio. Maybe a Ninja caliper could be fitted onto my fork if i fab a braket?
 
Re: KZ 400 Kawakazi Build

If that connector in the middle has to connectors sticking out of it that's for your brake light connection. I had that on my 750 in the middle and I ditched it for a single straight through cable.
 
Re: KZ 400 Kawakazi

Tonight i tried starting the bike. I got a spark on both sides, got gas in my carbs, battery is fully charged but it doesn't start, not even a bite. I am wondering if my timing is not right. So i took my spark plugs out and valve covers and rotated the engine in search of some anomaly but could really figure out if anything was out of order. Does anyone know if there is something i should be looking for? Thanks for the help
 
Re: KZ 400 Kawakazi Build

Double check that your timing advance plate is in there correctly. That sounds exactly like
What my bike was doing. I'm talking about the spring gizmo behind the points cover. It opens and closes your points. I had mine 180 off. The only way I figured it out was by removing the spark plugs and tappet covers and watched where the pistons and valves were when the points are open. On a kz400....pistons come up valves close and then the points should open. My points were open when the intake valves were still wide open. I flipped that plate 180 degrees and she started on the first kick. I'm not saying that it has to be this but I would start there. Good luck.
 
Re: KZ 400 Kawakazi Build

MILLENNIUM FALCON said:
Double check that your timing advance plate is in there correctly. That sounds exactly like
What my bike was doing. I'm talking about the spring gizmo behind the points cover. It opens and closes your points. I had mine 180 off. The only way I figured it out was by removing the spark plugs and tappet covers and watched where the pistons and valves were when the points are open. On a kz400....pistons come up valves close and then the points should open. My points were open when the intake valves were still wide open. I flipped that plate 180 degrees and she started on the first kick. I'm not saying that it has to be this but I would start there. Good luck.
Click to expand...
Did some investigating today, even took the rocker box off to make sure everything was set up correctly and to no surprise it was. I realized that the cam sprocket can be 180 degrees of and timing will still align. Also the timing advancer cant be 180 degrees off, there is a notch on one side only. Here's a pic of how it's set up. Also as you mentioned the points should be all the way open when "T" aligns, but they are not. They open up once you rotate pass 180 degrees. I even tried rotating the plate with points 180 to have the points open at different time and still nothing. Still have spark, they even get a bit wet after all the kicking. I am wondering what else can there be. It has to be timing!
timing_problems_01.jpg
 
Re: KZ 400 Kawakazi Build

here is the post from when i figured out what was wrong with my bike.




"FIXED!!!!!!!!!!!!!!! She is alive!! I knew it would be something stupid. I had a feeling it was a timing issue. So just sat in the garage watching the valves go up and down with a flashlight in the spark plug hole. Then i noticed the points were opening at bdc. Duh... you cant put the timing andvance plate in wrong because the shaft is keyed, but you can put the tube that cams the points open on backwards. I had to take it apart to clean/grease it and I must have put it together backwards. Oh well. She started up on the first kick upon reassembly. It sounds great! I will be posting a video this afternoon. Thanks for all the Help."
 
Re: KZ 400 Kawakazi Build

Also remember that you have a compression and exhaust stroke. My points were opening on the exhaust stroke which doesn't work too well, hahah


veaone said:
Did some investigating today, even took the rocker box off to make sure everything was set up correctly and to no surprise it was. I realized that the cam sprocket can be 180 degrees of and timing will still align. Also the timing advancer cant be 180 degrees off, there is a notch on one side only. Here's a pic of how it's set up. Also as you mentioned the points should be all the way open when "T" aligns, but they are not. They open up once you rotate pass 180 degrees. I even tried rotating the plate with points 180 to have the points open at different time and still nothing. Still have spark, they even get a bit wet after all the kicking. I am wondering what else can there be. It has to be timing!
timing_problems_01.jpg
Click to expand...
 
Re: KZ 400 Kawakazi Build

"FIXED!!!!!!!!!!!!!!! She is alive!! I knew it would be something stupid. I had a feeling it was a timing issue. So just sat in the garage watching the valves go up and down with a flashlight in the spark plug hole. Then i noticed the points were opening at bdc. Duh... you cant put the timing andvance plate in wrong because the shaft is keyed, but you can put the tube that cams the points open on backwards. I had to take it apart to clean/grease it and I must have put it together backwards. Oh well. She started up on the first kick upon reassembly. It sounds great! I will be posting a video this afternoon. Thanks for all the Help."
Click to expand...
So I took the springs off the advancer and flipped the tube, the points open up when the cylinder is up. Gave it couple kicks and still nothing. I am gonna try fresher gas tonight to.
 
Re: KZ 400 Kawakazi Build

The shop manual i have says that you alight the "F" mark on the advancer and rotate the points plate till the points just start to open. The manual says to use and ohms meter when doing this but, you may be able to ruff it by eye and see if it helps.
 
Re: KZ 400 Kawakazi Build

Pop147 said:
The shop manual i have says that you alight the "F" mark on the advancer and rotate the points plate till the points just start to open. The manual says to use and ohms meter when doing this but, you may be able to ruff it by eye and see if it helps.
Click to expand...

Adjusted the timing to the shop manual specs and checked everything all over again still nothing. I am starting to think it is something els. Any ideas? Thanks for the help
 
Re: KZ 400 Kawakazi Build

So could it be electrical. Something I should be looking for?
 
Re: KZ 400 Kawakazi Build

so simple it's stupid, but look for any ground wires that might have come loose. i couldn't get lights or anything to work on my bike a few weeks ago when i tried to start it for the first time all year, and i ended up finding a ground wire that was disconnected. touched it to frame, and all lights came on, bike turned over, and all was good in the world again :)
 
Re: KZ 400 Kawakazi Build

Id make a simple harness. Just power directly to the coil, and power to the starter, with a push button. Spark, gas, and if the timing is right it should run.
 
Re: KZ 400 Kawakazi Build

It RUNS!!! Cant believe the issue was a clogged jet. I knew it had to be something simple. Also the tank has to be hocked up to the carbs, it creates a better vacuum. I also raised needles in the carbs and it made a world of difference. Seems like with Kz's everything needs to be perfect for them to run. I've been thinking about getting Mikuni's slide carbs. Anyone had any experience with them?
Current issue is i have to kick it for a while to get it started.
Also in the process of taking of carbs and fuel lines my side covers got destroyed, gas ate through the paint. I think i will never go back to rattle can if it comes to engine parts.
 
Re: KZ 400 Kawakazi Build

One more thing I will suggest is to take your gas lid vent apart and make sure it is clean. When I first got my KZ running this simple problem plagued me. It would run fine then create a vacuum and lose power (one cyl at a time) then shut off. It is a simple thing to do that is commonly overlooked with older bikes.
 
Re: KZ 400 Kawakazi Build

Autotek said:
One more thing I will suggest is to take your gas lid vent apart and make sure it is clean. When I first got my KZ running this simple problem plagued me. It would run fine then create a vacuum and lose power (one cyl at a time) then shut off. It is a simple thing to do that is commonly overlooked with older bikes.
Click to expand...

hmmm...could that be a problem with a '72 cb350? those symptoms sound a lot like what the PO told me was happening before he decided to sell it to me for $100 :) could it be that easy??
 
Re: KZ 400 Kawakazi

Happy Thanksgiving everyone. I am very thankful for all of your guys help on my first build. Currently i am redoing all the wiring and adjusting the carbs. The issue is it doesn't want to fire up right away. wondering if it has to do with fuel flow. Here's how it currently stands. Better pics are soon to come.
IMG_1918.jpg
 
Re: KZ 400 Kawakazi

MotorbikeBruno said:
what are your air/fuel screws set at?
Click to expand...
I tried couple different options. Currently its at 1.5 turns. Current jets are: Primary main 70, Secondary main 95, Pilot 35. They are Keihin Cv carb's that folks claim are a pain in the ass.
 
Re: KZ 400 Kawakazi

I have heard the same things about cv's but mine have proven to be the easiest starting most reliable bike I have. I bet once you get it tuned you won't have any problems with it. Or maybe I just got lucky.
 
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