1975 KZ400D - restore project

There aren't enough e's in CLEEEEEN to describe your bike. Very nice! Ed

Great job. Looks awesome!!!

Pulling the warning flasher didn't make it stop flashing? Then the bike has been rewired differently from the diagram.

The relay substitute for the warning flasher should work. It's pretty simple. The blue wire (switched power wire) might be a yellow wire according to some diagrams. And the black/yellow wire (ground wire) might be plain black. The green/white wire goes to the dashboard light and provides ground to the indicator light.

Don't forget pin 85 must be jumpered to pin 87 (not 87A if there is an 87A).

Looks fantastic! Hope to see it in person sometime!

Yeah, it's great work to be sure. Had a 76 kz400 that I bought new and some quick math tells me I was about 19 back then. I was riding along and a guy from my old high school in a turbo black KZ900 pulled up alongside and asked me how I liked my scooter? Haha.

Not long after I met him again at his old girlfriends house. He seemed a bit down, teary even. I was picking up his old girlfriend for a ride on my "scooter".

We had a good ride!!

Hey all!

My head gasket on this bike failed a few months ago (3 of the 4 valve stem seals were ripped and leaking badly)...Im just about done putting it back together and I have a question about the 2 bolts on either side of the head (in front of the spark plugs). What is the torque value for those? I have the Kawi service manual, and I cant seem to find this info. Also, the o ring type gasket for the valve cover isnt available anymore (book and online says to use grey/black gasket maker)...the one that was on there is so dry rotten...have you folks tried to recondition this one and also put the gasket maker under it? Or should I just fill the area with the gasket maker only? Perhaps there is some universal o ring type gasket on a spool or specific lengths w the proper diameter? The top end is CLEAN (we vap blasted the parts).

Also, to the guy who was giving me shit some posts ago on this thread about going over the motor before dumping all the time and money into the rest of the bike. I think that is something that has to be learned, mistakes made, to actually realize that if you have the rest of the bike 100% restored, its almost vital to take the motor all the way apart, check all the wearable things, get the parts vap blasted and do it right the first time. Thanks for that, I learned that with this bike. Take care all.

Took the bike out and its running great, no leaks on the top end. I do have another question if anyone has any info...the left side case, where the wires come through the front end of the bottom end, above the sprocket...still leaks no matter what I do. Back in the days, I dont remember having any issues with this...I didnt even think there was supposed to be oil on that side anyways...maybe a little in the bottom to lube the starter chain...IMO I think theres too much oil going to that side of the case, causing pressure (just a guess)...

Anyone have any input? Thanks!

No eBay APP ID and/or Cert ID defined in Kunena configurationSo some dirt could block the oil flow back passage and build up pressure.
BTW: here you can buy the o ring type gasket for the valve cover.

Jack_Mills wrote: Hey all!

My head gasket on this bike failed a few months ago (3 of the 4 valve stem seals were ripped and leaking badly)...Im just about done putting it back together and I have a question about the 2 bolts on either side of the head (in front of the spark plugs). What is the torque value for those? I have the Kawi service manual, and I cant seem to find this info. Also, the o ring type gasket for the valve cover isnt available anymore (book and online says to use grey/black gasket maker)...the one that was on there is so dry rotten...have you folks tried to recondition this one and also put the gasket maker under it? Or should I just fill the area with the gasket maker only? Perhaps there is some universal o ring type gasket on a spool or specific lengths w the proper diameter? The top end is CLEAN (we vap blasted the parts).

Also, to the guy who was giving me shit some posts ago on this thread about going over the motor before dumping all the time and money into the rest of the bike. I think that is something that has to be learned, mistakes made, to actually realize that if you have the rest of the bike 100% restored, its almost vital to take the motor all the way apart, check all the wearable things, get the parts vap blasted and do it right the first time. Thanks for that, I learned that with this bike. Take care all.

Well I told...….
As for the O-ring gasket try some small vacuum line from the auto parts store glued in place with rubber cement or tri-bond.


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Jack_Mills wrote: Took the bike out and its running great, no leaks on the top end. I do have another question if anyone has any info...the left side case, where the wires come through the front end of the bottom end, above the sprocket...still leaks no matter what I do. Back in the days, I dont remember having any issues with this...I didnt even think there was supposed to be oil on that side anyways...maybe a little in the bottom to lube the starter chain...IMO I think theres too much oil going to that side of the case, causing pressure (just a guess)...

Anyone have any input? Thanks!

Try a little tri-bond on the gasket.


.

No eBay APP ID and/or Cert ID defined in Kunena configuration

Scirocco wrote: So some dirt could block the oil flow back passage and build up pressure.
BTW: here you can buy the o ring type gasket for the valve cover.

There is no drain back on that side of the early KZ400s.
The late KZ400s and KZ440s do have a drain back cast into the lower case.


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...but there is supposed to be a bit of oil in the bottom on the left side, below the stator right? I am having a hard time with this...

I used black/grey gasket maker for the valve cover and its holding. Only ran it for about 15 miles so I could change the oil and what not. Thanks for that link, Im going to buy it for the future.