'76 KZ400D3 Re-Assembly

Hello KZ Friends! My first post here on KZRider.

I recently picked up this 76 400 for my first real project. In the pictures below you can see the current state. The engine and tank are on the rolling frame, the bars and controls are on, though the controls are disconnected, the signals and mirrors are on. The taillight, headlight, carbs, headers, mufflers, airbox, wiring harness, battery, and most of the electrical components are off, and I need to get some padding on the seat - or get a new one. there is also a small hole in the frame where one of the POs had shaved off a tab and gotten a little too deep.

The report from the PO is that the bike ran great before he took it apart and he rode it around regular. The kickstarter worked great, and the electric start also worked.

My plan is the following:

1. Re-mount and reattach the harness
2. "Fab" a battery mount directly under the seat and lay the gel battery on it's back
3. Re-attach the carbs, the fuel line, and buy some pod filters to go on the carbs - it doesn't seem probable to remount the airbox at this point.
4. Re-attach the exhaust.
5. Re-attach the controls, including refill and bleed on the brake reservoir.

At that point, I think I'll be ready to attempt restart and carb tuning. The carb is cleaned and tank is sealed - so I think I can at least get this far.

Notice the pics of the harness - and the new piece as well...(i'll have to learn what that is called).

Please give me your thoughts and suggestions!

Get a shop manual and start reading.
Normally I would recommend a repair manual like Cylmers or Haynes,
but your bike has been monkeyed with to much to start walking a beginner
thru each and every system. Once you have an idea of what's going on.
When you start reassembling the bike asking more specific questions will speed
up your progress dramatically.

.

Thanks. Yep I do have the shop manual too. I will definitely be back with with more specific questions.

I have a mostly stock D3 so if you have questions or need a pic or two let me know. There is also a forum dedicated to the kawasaki twins. It is not as active as this one but there is lot's of good information there as well.
kz400.createforumhosting.com/
There is also a lot of good info here:
www.kz400.com/index.html

Good luck,
Jim