KZR's Bikes of the Month for 2024

1976 KZ400 D3 Restore Project

  • Scirocco
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19 Mar 2018 16:38 #780475 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
Check the valve stem bend, (max. 0,05 mm), one turn around and shift to different shaft position.





if ok, next step...
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19 Mar 2018 16:44 #780476 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
Remove the carbon




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19 Mar 2018 17:00 #780477 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
and some more pics





Took me 5 minutes of work for one valve rough cleaning without mirror polishing i prefer.
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19 Mar 2018 17:47 #780478 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
No eBay APP ID and/or Cert ID defined in Kunena configurationIn all my searching and digging and learning about my kz 400s, Ive never seen this front fairing on any other small kz...it looks like the chips/1000 front fairing, but it says it fits a 400? Aftermarket? Anyone with any input?



Thanks :)

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 17:57 #780479 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
Why you want to buy new. You don´t know how bad or good your valves are.
The valve tools, (removal/install), you need are available on Amazon or evil-bay.

Valve spring compressor



Valve seal pliers




Valve shaft seal pusher



and always use a condom for the new valve seals.

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19 Mar 2018 18:04 #780480 by Scirocco
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19 Mar 2018 18:43 #780484 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
I took the saddle bags and front fairing from my 77a1 and put them on the 75. I just bought another set of oem bags for the 77 (which is gonna be the next build) after I get this 76 done. The 75 should be done in a few weeks, once the guys are home from bike week, they can concentrate on helping me finish the bodywork and paint, etc. The 76 that Im working on now, is not getting a front fairing or bags, just plain jane, with some cool illusion green powder on some parts and a slick paint job. I do know that this 76 leaked like a son of bish, so at very minimum the value guide seals must be replaced. I hope the valves are good enough in spec that I dont have to replace them, but given that most of these early 400s leak like crazy, I should know how to fix, replace and tune them, so I can do the job myself moving forward. I really appreciate the time you guys give lending out valuable info, glad this site is around. :)

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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19 Mar 2018 18:49 #780487 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Where at in Germany are you located? I have friends in Heinsburg (Ive djed at Himmerich a bunch of times) also in Cologne , Berlin, Frankfurt, Aachen, also Freiburg (the water streams in brick down the streets is very cool there).

In regards to the picture, that a1 or a2 is super clean! I just wish Kawi chose a different color, that brownish orange is an eye sore :O hahaha

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 20:00 - 19 Mar 2018 20:01 #780489 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
I am located near by Dortmund.




I

In regards to the picture, that a1 or a2 is super clean! I just wish Kawi chose a different color, that brownish orange is an eye sore :O hahaha


This makes your bike very special and extraordinary!!!
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Last edit: 19 Mar 2018 20:01 by Scirocco.
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20 Mar 2018 13:26 #780513 by DoctoRot
Replied by DoctoRot on topic 1976 KZ400 D3 Restore Project

Scirocco wrote:
and always use a condom for the new valve seals.


what is that on top of the valve stem?

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20 Mar 2018 14:29 - 20 Mar 2018 15:05 #780516 by Scirocco
Replied by Scirocco on topic 1976 KZ400 D3 Restore Project
This is a plastic tube that goes over the valve stem (valve keeper groove), to protect the sealing lip cut and damaged by the sharp edge of the valve keeper groove.
You can easily destroy you new valve seal without this tube.
You can also use a suitable drinking straw.




Next Gen anti blow by valve seal.

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Last edit: 20 Mar 2018 15:05 by Scirocco.

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29 Mar 2018 20:23 #780986 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Restore Project
Finally had a chance to get back to the shop and get some stuff done. Got some blasting, sanding and prepping done today for the wheel hubs and rims. Hopefully I can get to the shop tomorrow and powder these parts :)

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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