my first project, 1978 kz 400 (now with 440 bits)

Shermanator86

Big guy on a little bike
Got my first bike in may, between finishing school, moving, and starting a new job I didn't get to working on it til late June but here is what has been done so far


pretty much how it was when i picked it up except the exhaust

after about two hours of the first day of work

quick rattle can job to see how white looks

didn't really care for the solid red stripe so went for a little more subtle one

how she left my buddies house after keeping it there for a month with his '76 survivor he pulled out of his grampa's basement and it had been through a house fire
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

first try at a single carb set up useing a keihin PJ




wasn't done very well do to my limited tools so i sucked it up and took it to a guy with a fab shop, pretty happy with the result




Changed the fork seals got new bars and grips along with new headlight, signals, and led tail from dime city


new bars

New headlight and front signals



old brake light and signals

new rear signals, tail light and license plate/ signal bracket I made out of some scrap we had laying around the farm shop



scrap born license plate holder/turn signal bracket



And here is how she sits as of now, i have a clutch push rod oil seal on the way that i hope to get in before I try to make the 150 mile trip to Indianapolis for the moto gp race at the end of the month
 

MNBikerPup

Newbie Rider into all motorcycles.
Re: my first project, 1978 kz 400

How does it perform with the single carb vs. duel carb setup? Do you notice a difference at all? I have a quad carb setup on my kz650, which also means more expensive repair/tune bills.
 

dustywang

New Member
Re: my first project, 1978 kz 400

Looks great. i love my single carb setup on my 76 kz400. Sooooo much more top end power. What size carb are you running?
 

MNBikerPup

Newbie Rider into all motorcycles.
Re: my first project, 1978 kz 400

I have the mikuni VM22/210 x4 carb set up. (which I think was the stock carb) I had thought about making it a duel carb setup where the carb makes a 90 degree outward turn and mount the filters on the sides. Kinda like the harley side filter setup, but for both sides. Or even run the carb setup under the seat to fill and clean up that area that is usually covered by side covers.
 

MNBikerPup

Newbie Rider into all motorcycles.
Re: my first project, 1978 kz 400

What did the shop charge you for this setup? (Just to get a ball park figure)
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

thanks guys, I don't really have anything to compare the single carb to as the stockers were junk so the bike didn't run with them and the single isn't jetted right yet so its running rich. and the carb is a keihin pj34
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

Ok so Planning on riding 3 hours to the Indy motoGP race and this is how my bike looks haha
:?

all because of one little seal

case split to replace seal



on a positive note, the seal is in, case is back together and should be finished up just in time to get my new jets in tomorrow and do some test riding friday hopefully
threw a little engine enamel on the intake to keep the rust off, turned out better than i expected
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

Well had a 6 hour night of putting the engine back together, put it back in the bike and got it re jetted and running. tired as all hell this morning but am still happy its done except for a little more tuning. So as she sit now its got a new clutch shaft oil seal, two new tires, new gaskets, and re jetted the carb. as I write this I just realize it doesn't sound like that much work haha

motor back in the bike

Little closer to done

new front tire

new rear tire

done

One more, can't believe how much of a difference the tires make
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

This past weekend I ended up getting a 440 top end with good pistons and rings, and a master cylinder off and unknown honda that I'm hoping someone on here can identify. Now need to get a 440 head gasket and its looking like a 440 cam chain tensioner as well, everything else should swap over from the 400 parts. Also sending the head to a machine shop to clean up the valves


top end



master cylinder

 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

well got some of the parts ordered to get the 440 swap started hoping to get started tomorrow or thursday and getting the motor out and torn apart. after talking to what i consider an expert on another forum it looks like I'm better off trying to repair my old head rather than use the new one due to cam issues. Also thinking about just going ahead and painting the frame while the motor is out, don't know yet we'll see how ambitious I feel, just getting over strep throat so not feeling 100% quite yet.
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

Well case is split again ready to replace the cam chain guide tonight. honing the cylinders cleaning up the pistons and reassembling the bottom end is the plan for the night but I snapped a bolt off in the case so have to drill that out first hopefully it goes smoothly. Then it just a waiting game for the head to come back from the machinist.
 

Shermanator86

Big guy on a little bike
Re: my first project, 1978 kz 400

Got word the head is done now, got the cylinders and pistons set last night so if all goes to plan should have the engine all back together and hopefully in the bike tonight
 

joeyputt

The green flag sets me free
Re: my first project, 1978 kz 400

Brother I can really appreciate how much hard work you have put into your 400, she looks really nice and I love the single carburetor!
 

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