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ThatGPzGuy wrote: There may be bulb available for the 400 but I never found one that fit the stock bucket. I ended up getting a new Emgo chrome housing with an h4 style bulb.

I went with the SpeedMotoCo version: H4 bulb with a black bucket and chrome ring, using the stock mounting brackets, on my '79 400. I did need to shim the mounting bolts a bit, so I alternated flat washers with rubber washers to make up the width (and maybe to reduce vibration).

Jack_Mills wrote: I got the gauges mounted and such on the bike yesterday. Bought a LED headlight, but its a bit small, and wont fit the stock housing properly. Does anyone know of a specific brand or model number for a housing for the standard HD LED type light 7 inch? .

There is [ or was ] a headlight available for a small Honda that is a direct replacement for the KZ400/440 with an H4 bulb.
The KZ400/440 uses a 6 1/4 in. headlight assembly.


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Today was a productive day working on the bike. Polished and cleaned the carbs. The first rebuild kit I bought on Ebay claimed to be for my bike, but was in fact not. Thanks to the guys over at Z1, who got me the proper rebuild kit (minus the main jet). Also cut the old spokes off and started media blasting the hubs in prep for powder. The replacement 3 ohm coil I got from Z1 didnt really fit the way I wanted, so the owner of the shop, Tim, bent the mount and we got it sitting pretty nice. Also, much thanks to the guys here who gave me great info about restoring the switches on the handlebars. The 77 Cadaver has the exact same switches, so Ill be taking a few parts from those and making two restored ones. The carbs should be rebuild and back together tomorrow evening, super excited! Oh I also sanded the headlight bucket...weirdest thing ever, the base coat paint was this purplish/brown color, that Ive never seen on the 75...perhaps it was replaced at some point before I bought it, no clue. I started working on the seat, and the entire time I've owned both bikes, I never knew about the paperwork compartment. Check the pics, I was hella surprised on the condition of the manuals!

Your project looks like it's going along nicely!

I'm down here in Washington, pretty close to you - I have a pretty rough '81 440 I've been playing with for almost two years now.

Wicast3, I also have an 81kz400 done w a bunch of extra parts left over. If youre looking for something specific private message me.

I have found that those piston slide carbs need a lot of finesse when installing the slides. The top cover can hinder the piston movement if it's not aligned properly. I find they always need about one drop of oil on the outside diameter of the piston and one drop in the center shaft. Then the trick is to reach in and move the slides up and down with your finger as you slowly tighten the two screws a little bit at a time going back and forth to each screw. Make sure the slide moves freely all the while. If it suddenly moves slower, see if you can find out why, or start over. Try to put the parts into the same carb they came out of.

Good luck on the project. I always liked those Deluxe 400's.

Got a lot of mediablasting done today. Rims and Hubs are soon ready for powder. Tim from Unit 6 Motoring fabricated the 5 3/4 projector headlight so it will fit nicely in the stock bucket. Tim kicked some ass today with that! Got the center stand from the cadaver and other parts ready for powder. We had to heat up that hollowed out metal tube that the center stand mounts to. Was a pain in the ass. That happened on my 81 400 as well. Cleaned, blasted and polished some of the rear brake components too. Hands are sore from polishing and I sure am glad I have the 77 cadaver to look at when I wonder in my head where this part goes!

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Looking really good Jack. One of these days I'll have to get going on mine. Right now it's just a good running (but not stopping) survivor.

Just put 12 hours into the bike, long day, but well worth it. Got the rear brake components all cleaned, painted and mounted. Got the center stand painted and mounted. Got 3 of the footpegs cleaned up, painted n mounted. Got the chain guard on, got the airbox cover painted and mounted. Tore the old seat off the pan and started blasting that, but I broke the mediablaster 1/2 way through that! My friend Blake finished up the carbs and we got them installed for the most part. Ran the cables, got the left sproket cover on the motor. Painted the headlight bucket. Tim, from Unit 6 Motoring mounted the coil and ran the plug wires. Got the hubs and the rims painted, they look good! All in all today was a busy and productive day on the 400!

Got some fresh wheel bearings and rubber, the bike rebuild is going great

Got some more work done yesterday on the bike. Got the seat pan blasted and ready for paint. Replaced a few things on the cosmetics of the carbs, got the left footpeg and kickstand mounted. Blasted the turn signal and kill switch switches, Im glad I have the cadaver cause the guts of both switches were nearly rusted away. Got some more stuff finished with the headlight. Got the triple tree and other fork bolts cleaned and tightened. Mounted the front fender support and front brake caliper. Mounted the handlebars. My friend started to get everything ready to respoke the rims, cant wait for that to be done.

I also picked up a fairly clean 76 kz400-D3 for a really good price. Another project for another day!