1975 KZ400D - restore project

loudhvx wrote:
For some reason, I can't find that crankcase oil seal on any fiche, not even for the 2nd gen Kz400 motor cases. Sometimes there is a note next to an oil seal which says whether the cases have to be split to replace a seal. I was actually looking for that note, but I can't even find the actual seal on the fiches.

Maybe someone with more coffee on hand can find it.

part# 92050-064

www.cmsnl.com/kawasaki-kz400d-1975-canad...050064/#.XdL3DrmWw_w

Started the seal job and realized I didnt have the proper puller, so I ordered one. When I took the left side dynamo cover off, it was full of oil. Looks like it was leaking at the wire rubber and there mustve been so much oil in there that it was pushing through the starter area and dripping out of the bottom of the starter drain above the sprocket. Thanks for the link to the inner oil seal...Im pretty sure that requires the bottom end taken apart and Id rather have a little bit of oil leaking than to tear this motor down again haha!

I wonder if a drain hole or two could be drilled in the earlier cases without damaging any thing? I reckon the cases would have to be split in order to remove drilling debris.

Also, beware, that bolt holding the rotor is left-hand thread. The bike I was working on had the bolt sheared off in the crank since the previous owner obviously didn't read the manual.

(The puller is right-hand, normal, thread.)

TexasKZ wrote: I wonder if a drain hole or two could be drilled in the earlier cases without damaging any thing? I reckon the cases would have to be split in order to remove drilling debris.

The hole can be drilled right in the center directly below the crank.
This is where the later engines have it. But the hole WILL be a two-way street.
That should not be a problem thou.

So Ive got the left side torn down. Comes to find out there are 2 seals. The outer seal was ok but the inner seal was totally shot.

The outer seal (which is mounted on the front starter sprocket) is Kawi # 92050-066
The inner seal (which is mounted on the inner case) is Kawi # 92050-064
Both seals are accessible without tearing the motor down.
Ive gotta clean the area up here in a bit, and wait for the other seal to arrive. Have a good day!

Uhh I always have problems uploading photos...mods if you can delete the dupes?

Jack_Mills wrote: Both seals are accessible without tearing the motor down.

That's great news. Thanks for the info.

What kind of pipes are those? I really like that.

The guys at Unit 6 Motoring in Pittsburgh and I made them using the factory head pipes and welded/built the rest of it, put some baffles in for back pressure. Its loud but its throaty and the bike runs great.

Did you have to jet the carbs to make that work? I have an aftermarket set of Macs on my 76 400 and I would like to either go back completely stock or go full mod like you have done.

Wow - Jack, very impressed with your work - the patience and diligence for these old bikes is something I'm finding in short supply. Question for you about the starter and chain you replaced. I bought the same bike - 75 kz400 blue - but it was halfway through a restore, so I'm taking it over after someone else tinkered on it for a couple of years. The starter chain they had on was quite loose. I couldn't figure out any mechanism for tightening it, so assumed it had somehow loosed/lengthened over time., or had been replaced with a wrong part, etc... So I found another - same year, etc. - and it's the exact same chain - and just as loose. It actually bangs the sides of the case when turning over. Any ideas what that could be?