KZ 400 Kawakazi Almost Finished!!!

[7aliveatlast7]

thanks for those pics man! sorry for all the questions, but what is your seat pan made of, and how is your seat cover affixed to it? i don't see any staples or rivets on the underside of your seat, it's got me curious, ha. hopefully some new jets straighten things out for you!

 

[veaone]

thanks for those pics man! sorry for all the questions, but what is your seat pan made of, and how is your seat cover affixed to it? i don't see any staples or rivets on the underside of your seat, it's got me curious, ha. hopefully some new jets straighten things out for you!

The seat pan was cut out of 22 Gauge sheet metal, bit i would recommend going a bit thicker. The cushion is 3 layers of thick yoga mat glued together.I also rounded the corners with a sanding wheel. To get it covered in vinyl cost me $80, he just glued it to the pan.

 

[veaone]

Thanks for the shots of the battery/electronics box. I'm working on mine right now, so that helps a lot. I love how yours just looks like part of the frame. Are you planning on using the electric starter or just kick start? I was considering switching to a Shorai battery but the one they spec out for the KZ400 w/elec start is no smaller than the AGM battery I'm currently using though I'm sure it weighs a lot less. But it takes up the majority of the space I have for the battery/elec tray. But that Ballistic battery looks tiny - that would def help in trying to fit everything else in there.

I have electric starter hocked up already. I rarely would use it though, it can drain your battery pretty quickly. Ballistics battery has been good so far the size is perfect.

 

[veaone]

Yeah those cables are a pain.....I had similar problems. As far as your starting problems go, you may have already posted this, but what jets are you at right now? I am running vm30's on my xs400 and I had to re-jet several times to get it right. I am running 150 mains and 28 pilots. Keep in my my carbs are 30's so yours might be different. I was told that 32mm carbs were too big for 400cc bikes. I dont have first hand experience with this but i have heard it more than once.

I did a little research and some folks run the 32's with no problem. The stock jets are 200 main and 35 pilot. I just ordered some 180 and 150 Main, 27.5 Pilot. Will see how that works out. I saw the new sidecar you got. That thing looks so sweet!

 

[MILLENNIUM FALCON]

Good, I hope it works well for you. I'm sure with the right jets you will get have her running like a champ in no time! I am pretty excited about the sidecar. Sidecars are new to me so it is a learning curve. Keep up the good work.

 

[veaone]

Got this guys as a Christmas gift for my KZ.

I got them installed and she fired right up. The carbs have been also rejeted to 27pilot and 180main. Runs a lot better, gonna down jet to 150 mains next.

 

[Scruffy]

Just saw your build thread. Excellent job, I'll be happy if my CL project comes out half that nice.

What rear shocks are those, the 40+ year old Cerianis on my bike are about worn out. I've got the same handlebars on mine as you run, but mine are chrome (beggars can't be choosers and they were cheap). Had grips like yours on the stock handlebar, the more you run them the better you will like them. I even used a set like that on my GS750T. No hand fatigue at all.

 

[veaone]

Just saw your build thread. Excellent job, I'll be happy if my CL project comes out half that nice.

What rear shocks are those, the 40+ year old Cerianis on my bike are about worn out. I've got the same handlebars on mine as you run, but mine are chrome (beggars can't be choosers and they were cheap). Had grips like yours on the stock handlebar, the more you run them the better you will like them. I even used a set like that on my GS750T. No hand fatigue at all.

Thanks. The shocks i got on ebay. I think the name is RFY and they work descent, definitely an update from the stock. The grips are very comfy to, i think they are air filled.

 

[veaone]

Not much new to report. Waiting for another pair of jets. I tried 180s and it runs a bit rich and 150s run a bit lean. So i am gonna try 165's this time. One issue i ran into is that the pods dont fit anymore. The frame is way to close to the new carbs and the battery box gets in the way to. Does anyone know what could be a smaller alternative version for an air filter?

 

[diggerdanh]

I ran into a similar issue with my battery box, luckily I was making it out plastic the first go around so I saw the issue before I had a sheet metal one made. Our frames are a little different, I have a single drop tube there at the back of the engine cradle where you have a double. But the same filters I used may work for you. They are K&N RB-0600 with a 3.5 inch OD and 4 inches long but they have a 5 degree angle offset. I had to use that angled offset to point mine "out" to clear the down tube but you may be able to point that angle down and clear your tray:

http://www.dotheton.com/forum/index.php?topic=37948.msg495134#msg495134

http://www.knfilters.com/search/product.aspx?prod=RB-0600

Or you can check the K&N round straight and round tapered filters to figure out what will fit. Look for a 2.25" / 57 mm inside flange ID to fit the VM30s:

http://www.knfilters.com/search/univround.aspx
http://www.knfilters.com/search/univcone.aspx

You can also check the Uni filters:

http://www.unifilter.com/clamp_on.html

UP-4229AST are 4" long and have a 4" OD but part of that is the foam cover but they have a 15 degree offset. Or PK-92 (2 per kit) are straight but only 3" OD and 3" long.

Lots of stuff to choose from just depends on what look you want and if they will fit.

 

[diggerdanh]

And I'm loving the feedback on the carb jetting. Thanks and keep it coming - it'll give me a great place to start!

 

[BLSully]

Whoa, nice resource for the carb settings... I have a pair of vm32s which will be going on my 400 this spring. Sounds like I will be starting with 27.5 and 165. Any idea what needle jet and needle you are running?

 

[veaone]

I ran into a similar issue with my battery box, luckily I was making it out plastic the first go around so I saw the issue before I had a sheet metal one made. Our frames are a little different, I have a single drop tube there at the back of the engine cradle where you have a double. But the same filters I used may work for you. They are K&N RB-0600 with a 3.5 inch OD and 4 inches long but they have a 5 degree angle offset. I had to use that angled offset to point mine "out" to clear the down tube but you may be able to point that angle down and clear your tray:
http://www.unifilter.com/clamp_on.html

Thanks Man, I just ordered uni filters and i hope i can mod them to fit my set up. I'll keep you posted on how the jetting goes.

 

[veaone]

Whoa, nice resource for the carb settings... I have a pair of vm32s which will be going on my 400 this spring. Sounds like I will be starting with 27.5 and 165. Any idea what needle jet and needle you are running?

The carbs came with the standard 159 P-5 Needle Jet and 6DH7 Jet Needle. There are five notches on the needle and i have it set on the 4th one from the top and it seems to run the best. I'll post an update on how it runs with 165s soon.

 

[marla_do]

new favourite.

 

[NBraun]

Absolutely sweet bike! Just one question. where did you get those grips?

 

[veaone]

Absolutely sweet bike! Just one question. where did you get those grips?

I got them on ebay. I think this are the ones. http://www.ebay.com/itm/Vintage-Motorcycle-Grips-/251096093674?pt=Motorcycles_Parts_Accessories&hash=item3a767e53ea&vxp=mtr
They are very comfy just make sure they fit snugly, the right grip sat a bit loose over the throttle on my kz and used some electrical tape to make it fit right.

 

[ako]

Running wires straight through a sheet metal bulkhead is not a good idea (black wire above battery). It will chafe and short out.

You need a rubber grommet there.....

 

[Bert Jan]

sweet ride! knobbies look goooooood

i'd put some plastic washers between the seat and frame, to prevent scratching and such. holes in those tubes are not such a good idea when it comes to strength, but as they're only m6, i guess it'll go ok.

 

[Autotek]

I am running the 32s as well on my kz400 and I think I have 155 mains now and it still boggs off the line especially when its cold. I wish I had bought the 30s instead. Idling off from the light simply wont happen. I am hoping to drop down again and fix this problem. Unless I am missing something?