KZR's Bikes of the Month for 2024

1976 KZ400 D3 Restore Project

  • Jack_Mills
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30 Jan 2018 21:17 #778053 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Got most of the parts blasted this evening :)

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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09 Feb 2018 01:31 #778411 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Well Im over near Amsterdam, and I got to stop by CMSNL's warehouse. They have 5 floors of vintage parts for all types of bikes! Picked up some rare parts for my 76! Got to my apartment over here and these beauty's were sittin on my desk. Found them in a small shop near Copenhagen Denmark :) Ill have some stuff to work on when I get back home!

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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  • Jack_Mills
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04 Mar 2018 22:08 #779763 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Picked up another 76 to pull parts from for my build. Frame should be done powdered this week and then I can start cleaning parts and putting it back together :)

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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  • Jack_Mills
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07 Mar 2018 00:34 #779856 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
As the guys finish up the 2 show bikes for bike week next week, I got busy with preppin and powdering some parts for my 76. The 75 is gonna have to wait until after bike week to get finished, so this worked out nice. Picked up the main part of the frame today from a fella who has a bigger oven, he did a great job. I put 18 hours in the shop today, got a $hit ton done. Happy to be back working on the bikes :)

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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08 Mar 2018 04:06 #779909 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
As I start to rewire this one, I noticed a few splices in the harness jumping to ground on the cadaver I bought. Its similar to the 76 Im rebuilding, splices in similar areas going to ground. Im curious if any of you gurus have any input on why/reasoning behind this? Its confusing...if you look at the 2nd picture, you will see me holding a white wire that was connected to the ground, but its going through the fusebox/fuse?? Thanks for any info/input.

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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08 Mar 2018 06:13 - 08 Mar 2018 06:50 #779911 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
The white wire is always the main + Voltage power wire ( battery +) and should never connected or short cut to the ground or battery negative without any electrical device or heavy load resistor.



This browser does not support PDFs. Please download the PDF to view it: Download PDF

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Last edit: 08 Mar 2018 06:50 by Scirocco. Reason: Add pictures and electric manual
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08 Mar 2018 23:30 #779962 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Thanks, Im pretty sure the d3 and the d4 have the same wiring. I plan on re-wrapping the harness tomorrow. I powdered alot of parts today. Helped the crew finish up one of the bikes for Daytona next week, in typical week before fashion, 18 hour days :)

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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11 Mar 2018 06:41 #780056 by Nebr_Rex
Replied by Nebr_Rex on topic 1976 KZ400 D3 Restore Project
Some kids never grow up.


.

2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


.
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13 Mar 2018 04:24 #780153 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Haha ^^ I had a big wheel as a kid, funny post :)

So I got some more done on my 76 rebuild. Gonna work on the motor a bit today, my fingers are raw from polishing, but thats how it goes I guess!

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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  • Scirocco
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19 Mar 2018 16:20 - 19 Mar 2018 16:21 #780470 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
Hello Jack

Here some pics for your valve maintenance.
Tools you need




Check the valve shaft for damages like scratches, dents, pitting or other stupid things the PO does.





If you seen things like this buy new valves.
Last edit: 19 Mar 2018 16:21 by Scirocco.
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19 Mar 2018 16:26 #780472 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
I have a feeling Im going to need new valves...thanks for the info, I appreciate it greatly.

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.
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  • Scirocco
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19 Mar 2018 16:30 #780473 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
If your valve shafts looking good go to the next step, valve stem diameter (min. 6,90 mm)




if out of spec bring it to the old metal recycling
If not next step...
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