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1975 KZ400D - restore project 20 Dec 2017 20:09 #776444

  • Jack_Mills
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No eBay APP ID and/or Cert ID defined in Kunena configurationWent looking for a starter rebuild kit, seen several but does anyone know which would fit for starter 21163-1011 ? Seen one that has a matching part number but doesnt include the 75 in the list....although the 74-75 are the same I think
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
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1975 KZ400D - restore project 22 Dec 2017 15:35 #776508

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Started the day getting the rear hub and such mounted on the bike. Also finished up the switches on the bars, they look and work great. The starter used to act up back in the 90s and I almost forgot about it, until we went and turned it over. Got the side cover off, and holy hell, it looks like coral was growing near my stator :woohoo: Started to remove the starter, and whomever owned it before me, broke both 10mm bolts halfway off, wtf! So now we have to drill those out, but we ran out of time today. On the way home I smashed a big buck, ran right out in front of me. Wasnt such a great day, but theres always tomorrow!
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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1975 KZ400D - restore project 22 Dec 2017 16:16 #776509

  • Scirocco
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What the f**k could you miss this piece of s**t under the stator cover?
Never seen such a lot of (German language: SCHEISSE = shit) under a side cover.
A good clean with a stainless brush and a lot of of WD40 will solve your problem

Have a nice Christmas
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1975 KZ400D - restore project 22 Dec 2017 19:09 #776521

  • M_a_t_t
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If you are like me you will feel good after you get that crud cleaned out of that cover. BTW did you mean starter on post #776443? it says horn but you started talking about the starter.

Bike is really sharp looking
83 KZ1100A (shaft)
17 Versys X 300 abs
81 kz650h1
81 kz750e2
90 Honda CBR600F (brother's)

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1975 KZ400D - restore project 23 Dec 2017 00:14 #776534

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The horn wasn't working, I plugged the cadaver horn in, and it worked, but it was beat up. Bought an aftermarket for 14$. The starter is messed up. Some previous owner broke both mounting bolts for it half way off. Z1 has a clutch starter rebuild kit, but that part is fine. Im having a hard time locating the proper starter rebuild kit for my bike. We were thinking, if a bearing or something is shot, we are gonna grab the 77's and rebuild that one.

I literally have to shop vac the crud out of that side case. Never seen anything like that before, but I do remember riding that bike in the rain and snow alot. Got a new gasket, and will get that all cleaned up.

Its gonna be a busy few weeks, wont get to work on the bike till next year...
Merry Christmas!
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
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1975 KZ400D - restore project 24 Dec 2017 09:42 #776582

  • Jack_Mills
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No eBay APP ID and/or Cert ID defined in Kunena configurationI am selling the NOS 85mph/140kmph speedo I originally bought for replacement on my bike. Although it fits, its not the stock one for my bike (the 120mph one is). If any of you are looking for a mint NOS speedo, the link below from ebay is where to find it. I have it listed for 125$ a few bucks cheaper than I paid for it, but no reasonable offer will be refused. I just hope someone can use it for a rebuild project. 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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1975 KZ400D - restore project 03 Jan 2018 20:17 #776887

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Finally got back to working on the bike today. Got the starter out, and it was a pain! A previous owner broke the 10mm bolts off halfway through. We got them drilled out, then found out they were also broken into the bottom half of the motor. Couldnt get those out, so we will drill them out and retap at least one so the starter has something to ground to and to keep it steady. I bought that starter rebuild kit I posted a few posts earlier, and of course, it wasnt the right one. Not even the brushes were the same size, as the ad claimed. Lucky for me, theres not too much to these starters. I took it apart, cleaned everything real good and put it back together, and it is working nicely now. Cleaned up the crap that was in the stator side case also. Hoping to have the front rim respoked tomorrow, so I can finish the front end. It will be a busy day tomorrow working on the bike. We are getting close!
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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1975 KZ400D - restore project 04 Jan 2018 18:27 #776936

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Got a lot done today. Mounted and secured the gauges (again) headlight back in, new horn installed. Cleaned up some more of the stuff around the stator. Tim tapped a new thread for the starter, got that all back together, waiting for a nos slipper as I noticed it was half ripped off and rotten. Got the carbs back in place. Cleaned up the pipes and put them on the bike just to make sure everything fits properly. Going to get the pipes ceramic coated, and we are thinking of getting them done gold similar to the stripe on the bottom of the gastank. That also will match the spoke nipples, chain and bolts on the new horn. The electrical system is functioning properly and the starter is turning over smooth. New horn is decent for 14$. Didnt get around to threading the front rim, hopefully soon. Going to start sanding the parts that will get painted the blue color scheme. I really cant wait to start her up!
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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1975 KZ400D - restore project 04 Jan 2018 18:40 #776939

  • ajsfirehawk
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Great progress. The stator area was the worst I've ever seen. Keep pitching you are winning.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1975 KZ400D - restore project 05 Jan 2018 05:20 #776947

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Ok Kawi KZ guru's...I have a question for you. So as you know I have a 77 kz400a1 as a cadaver. We took the front faring, the luggage rack, saddle bags and mufflers from the 77 and are putting them on the 75. I've been using CMSNL and a few other places to buy/view parts and such. The mufflers from the 77 have the tapered ends vs the straight ends from the 75. From all the schematics Ive looked at, I can not find these mufflers (but every 77a1 and 78a2 have said mufflers on them). They are 2 separate mufflers, not 2 into 1. They dont have the cross bar/support under the motor like some do. Unlike the 75 mufflers, the 77a1 mufflers have a rubber grommit that the metal plates attach through. I can not find these grommits anywhere...but I mean I cant find them on any schematics either. Im sure we could make them or cross ref something to work, but I was hoping to get the exact fit grommits, since we are getting the mufflers ceramic coated. Can any of you shoot me a link to a schematic or perhaps you are familiar with what Im speaking and offer any advice? Much 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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1975 KZ400D - restore project 05 Jan 2018 10:45 #776970

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Kawasaki and Partzzilla show that mufflers with that mounting system are from the A2. They show the A1 as having a bolt-on triangular bracket. Sadly, no mention of the grommet on either.....

www.kawasaki.com/Parts/PartsDiagram/142560/1977/KZ400-A1
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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1975 KZ400D - restore project 05 Jan 2018 11:30 #776974

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Here is a pic of the mounting hardware before powder, they are the 2 triangle parts in the middle. One of those holes goes a bolt through a grommit and such to hold it into place. Here is a picture of them on a kz 400b i.pinimg.com/736x/74/75/35/74753541e9f90...cars-motorcycles.jpg then after looking at that I went here www.cmsnl.com/kawasaki-kz400b1-1978-cana...t/51466.html#results and it def doesnt have the cross pipe/support pipe as shown in the specs. It is the pipe, just without that cross.

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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