Hi from NorCal

Not sure if I communicated clearly with the "Rosy Picture". You may have got it right but just to clarify, I meant that I am impressed with your postings and your positive attitude. AND, I have no doubt that this KZ of yours has found a good home. Keep momentum going and please keep us posted on your progress.

Ha ha. Got it. I think it's in good hands. My buddy's didn't seem too stoked to do all the work, but I've been enjoying it.

Last weekend I got a chance to pressure wash the trailing arm and where the pipes cross. Also removed the sprocket cover and clutch cable, and cleaned that all out. I was careful to mask off holes with a thick beach towel, pulled a bunch of electronics up, and not too much pressure. Need to re-grease that trailing arm, but at least all the crud is out from there.

Doing the front end first. Front brake is off, and I got a new lever/reservoir coming. That was waay calcified. :pinch: Fork seals and oil are coming. I need to find a decent front tire. If anyone has any suggestions, then I will take them.

Thanks.

Replace both tires no matter how much tread is remaining. You mentioned the bike hasn't been ridden is 20 years before you received it, so both tires are no longer safe. Even if the tread looks good and there are no obvious cracks in the tires, the rubber hardens over time and will not provide you with adequate grip. This is a bad thing. Be sure to replace the tubes at the same time.

As far as what type tires, I am very pleased with the performance of the Pirelli Sport Demons. They grip well and last many miles. Metzeler (a Pirelli sister company) makes good tubes in sizes for our bikes. Ed

650ed wrote: Replace both tires no matter how much tread is remaining. You mentioned the bike hasn't been ridden is 20 years before you received it, so both tires are no longer safe. Even if the tread looks good and there are no obvious cracks in the tires, the rubber hardens over time and will not provide you with adequate grip. This is a bad thing. Be sure to replace the tubes at the same time.

As far as what type tires, I am very pleased with the performance of the Pirelli Sport Demons. They grip well and last many miles. Metzeler (a Pirelli sister company) makes good tubes in sizes for our bikes. Ed

Absolutely Ed. That was my intention. I am just doing the front end first, as to not get overwhelmed.
Thanks for the tire suggestion. I will check them out.

Hope you guys don't mind me continuing to update here. This is a 'rustoration', but I'm so newb that it might belong here. Wanted to throw up some progress pics, but I might get around to that later today or this weekend.

New brake master cylinder is on the bike, pretty stoked that it come with an extra set of rebuild parts. Nice new bright green brake line. On a side note, I think I'm going for black, and offensively bright 'Kawi' green for color scheme.
Rebuilt the fork and it feels niiice. Way better than before. I slapped the wheel back on so I could get er back in the work shop, as it has finally rained a little. We need the rain badly so doesn't bother me. :ohmy:
I tore into the brake caliper, blasting it out with brake cleaner, re-greased all the pins and slides, piston went back in easily. Just need to put the pads in and bolt it back up.
I should be getting tires this weekend. Gonna go ahead and get both, as I really don't need much else for the rear, besides shocks.
I decided not to mess with the head tube bearings at this point. A co-worker pointed out that the balls do get divots in them and feels like your falling in a turn if it settles into those divots. However, I yanked, pushed, and turned the head tube and only felt smooth operation.

Well, I should probably do the wheel bearings and the headtube bearings, if im gonna crack open a can a grease anyhow.

The handlebar dampers that I ordered do not fit. Part Number 92075-275 supersedes 92075-092 Seems way too big.
I ordered Part numbers 92075-039 and then looks like 21131-005 just to be sure I have a set that will work.

Good idea to replace bearings. One test I have used to determine if my steering head bearings are no longer good is; place front wheel on wax paper on a smooth floor surface. Move the handlebars back & forth. If there is any notchy or grabby feel to the movement the bearing are likely bad.

Another good tip for wheel bearings is to freeze them prior to installing. They will drop in to the hubs much easier and you are less likely to force then causing damage to the new bearing. Note: they may not "drop" in even if you freeze them. A non marring mallet of rubber or urethane and a flat wood block/board come in handy if you need to tap in place. Keep up the great work. You will have that ole KZ up and running in no time!

Ordered Bridgestone tires.
Progressive rear shocks PS12-1207B
Springs PS03-1394B
75-120Lbs spring rate (I weigh 175, no pssngrs)
I can confirm these bushings 92075-275 supersedes 92075-092 Do not fit!
But these bushings 92075-039 do work.


Need a chain..Seat reupholstered...Pulling carbs out again to hit the slow jets..need to sync carbs.

Charging system doesn't charge the battery. I get 12.5volts with the bike idling at 1k rpm.
Resistance between the yellow wires on the stator when set to 200 Ohms reads .7, which seems to be out of spec, the book says .26-.38. Does that mean I need a new stator? They are pricey, and sorta hard to find a new one for the kz400 ltd h1.
I get a reading from the regulator/rectifier, between the yellow and black leads one way, but no reading the other way, Does that mean I need a new regulator/rectifier? The book says I should get a slightly different reading one way or the other, but at least a reading both ways.
Good news is I got tires on the bike, found a shop that will recover the seat, new bright green chain. Other parts on the way, braided stainless lower brake line also green. Rear shocks should be here tomorrow...

I have to modify the chain guard little to get the shocks to fit.

That chain is obnoxious! I love it! Do they come in Blue?

Yes! They come in blue. Just search o-ring chain on ebay, and make sure you get the right pitch and number of links.
Slightly cheaper than the chain sold and recommended by some other online suppliers, but what the heck, it's freaking bright green....