79 KZ400 project

Hello everyone, new member here. Looking to find parts for my 79 KZ400-H project I just started and I'm having trouble. Would really like to find a parts bike with running engine, or at least a running engine or complete rebuild kit for my existing engine on the cheap. Have searched Google for hours and come up with minimal results. Please help!

What is wrong with the engine you have now?



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I won't know until I tear it down and inspect it. But if I'm going to go through the effort of tearing it down, I would like to at least rebuild the top end before re assembly. Can't find a rebuild kit for it, maybe I'm just looking in the wrong places, so for me it would be easier to just slap on a running engine and be done with that end of the project. I do know from the guy that I bought it from that it had no spark, but that is all I know about it. Just picked it up today and stripped it bare before it even made it off the trailer. Gonna start the sand blasting process this week and soak the carbs to prepare to rebuild them while I continue to research. Any technical knowledge on these bikes would be much appreciated!

:woohoo: Did you even try to start it and /or check compression?
I could give you all kinds of technical information on the KZ400/440 engine.
Reinstall the engine check compression and see if it will fire up.
No spark could very well be something simple. If you can't diagnose
a simple points ignition you are in for a very steep learning curve.
Asking about a 'kit' shows you are very unfamiliar with motorcycles.
Especially vintage bikes. Acquire a manual and get the engine running.
You just may not need to overhaul anything.


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Yes I can diagnose a simple points ignition. Kind of hard to attempt to start or compression test an engine with no battery, no kick starter, carbs removed, and half of the the ignition parts missing... Starting from the ground up on this one. Will disassemble the top end, lap the valves, replace rings, and inspect for any damage or wear. Worrying about internals first before I start throwing coils and condensers at it. I am very familiar with motorcycles, but have never worked on one of these old Kawasakis. I bought the bike as a basket case for $150 with half of the basket missing.... Will get a clymer, but in the mean time just trying to get some direction from people experienced with these bikes.

In your first pic there is enough there to check compression and spark.


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www.kawasaki.com/Parts/PartsDiagrams/1979/KZ400-H1
Start here get the part # I found it helps to find parts for the old kz's with the part #
It might be easier to get another parts bike and make one than locating all the parts you'll need. I haven't found a lot of aftermarket stuff for the kz400/440. EBay is your best bet for NOS
11thhourindustries.com makes a nice set up for a 2 into1 intake.
www.oldbikebarn.com is a good place for aftermarket parts.
www.z1enterprises.com also cares some stuff for the kz400/440

How can I check either if I cannot turn the engine over? I was able to just barely turn it over with a pair of vice grips to make sure it was not locked up, but do not want to damage the spline on the kicker shaft by going crazy trying to test compression and spark...

Thanks for the links Qyigleyje! Much appreciated.

You can generally turn the engine over with a spanner on the nut on the end of the crankshaft (R/H side ) under the points plate. (Forgive my lack of proper technical terminology). A workshop manual is always a great help,never understood how people can spanner away without them.
Advice given to me before I stripped my engine was to take it up the road and run it through the gears to make sure they are all doing what they should. Its not something you can do but maybe you can find some other way to check the gearbox.

P.S. Plenty of 400 builds on this site. Have a read through. Lots of answers to questions that may come up.

Gregbails485 wrote: How can I check either if I cannot turn the engine over? I was able to just barely turn it over with a pair of vice grips ...

If it still has starter motor then you can use a 12V battery and jumper cables. Positive to the fat wire to the starter and negative to the engine body.

Try to keep vice grips away from the bike.

JR wrote:

Gregbails485 wrote: How can I check either if I cannot turn the engine over? I was able to just barely turn it over with a pair of vice grips ...

If it still has starter motor then you can use a 12V battery and jumper cables. Positive to the fat wire to the starter and negative to the engine body.

Try to keep vice grips away from the bike.

And that is how you can check compression and spark.


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