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1975 KZ400D - restore project 12 Apr 2018 09:55 #781708

  • Jack_Mills
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This is the bulb I have in the rear brakeright now, perhaps not the same manufacturer (mines from Amazon) but it pretty much has the exact same specs and diodes...
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 12 Apr 2018 11:36 #781711

  • loudhvx
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Here is one option. It should be pretty easy to make.
You replace the brake warning unit with a standard automotive relay.
You can use the standard dual-87 relay or the 87/87A relay. Most parts stores have them.
They are named for the pin numbers on the bottom. Some have two terminals labeled 87, and some have an 87 and an 87A.

The bosch part number was 330-070. You can find substitutes with that number usually.

Kawasaki used a few different wire color combinations for the brake warning unit.
These wire colors are based on the 78 Kz400. You'll have to see if yours are different. If so, I can re-color the image.

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1975 KZ400D - restore project 12 Apr 2018 19:23 #781725

  • Nerdy
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loudhvx wrote: One remedy would be to put a resistor as an extra load in parallel. But that would defeat the purpose of the failure unit since it would no longer detect a burned out bulb. Also, then you are not saving any power. So you might as well use a standard 1157 bulb and the standard failure-flash unit.


OTOH, the LED bulb will be brighter and more visible so it's probably not a bad idea.

On my previous '79 KZ400 I replaced the turn signals with [much brighter] incandescent DOT models so I wouldn't have to monkey around with resistors or the flasher. The stock taillight was replaced with a much brighter LED arrangement, but I never had an issue with anything on the dash. Maybe that bulb was burned out. :laugh:
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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1975 KZ400D - restore project 13 Apr 2018 03:39 #781730

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I have a busy weekend of work coming up, but I am going to try to get to the shop earlier today to try to get some stuff done on the 75. I appreciate the input and help!
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 25 Apr 2018 18:59 #782372

  • Jack_Mills
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My buddy Zack got the parts primered tonight, they are looking real clean :) I cant wait to ride it!
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 26 Apr 2018 07:27 #782410

  • ajsfirehawk
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Ahhhh, if I only had a paint booth. Looks great. Just to see everything smooth and the same color, even if it is primer, feels great.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1975 KZ400D - restore project 26 Apr 2018 09:34 #782420

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The one thing we had to do with the 77a1 tank is cover over the emblem screw holes. Both side bolts (4) were broken off in the threads, and we couldnt get them out. No worries, the new emblems will work fine. I now have 3 full sets of a1/a2 bags and farings :)
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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Last edit: by Jack_Mills.

1975 KZ400D - restore project 11 Jun 2018 09:37 #784927

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Hey long time not chat everyone, Ive been extremely busy with work and what not. We are near completion of the 75 restore project. I have been sorting through 1000s of colors to try and match the blue, white, black and gold colors matching the bike/year. Do any of you have any current color codes that match the 1975 kz400d2 ? Ive searched with no luck. Thanks for any info, appreciate it.
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 15 Jun 2018 18:49 #785234

  • Nerdy
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You might be able to find what you need in here:

www.twowheelparts.nl/en/paint/colorpaint/kawasaki/
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R
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1975 KZ400D - restore project 18 Jun 2018 16:19 #785406

  • Jack_Mills
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Thank you, we went with a Chrysler metallic that looks pretty darn close. Parts are getting painted later this weekend.

There is one more thing I need to locate, and I am hoping one of the guru's here can help me. The original bag hinges were rusted and broken. Does anyone know of a company that makes quality aftermarket saddlebag hinges and locks? From the looks of it, I have 3 inches in front and 4 in back of bag to work with. Searching this on the net, gives me the long Harley/aftermarket Harley types that wont work for my application. Thanks for any input.
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 10 Aug 2018 16:01 #788634

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Had a lot of stuff going on the past few months with work and travel, but I got back to the shop the other day and we got the pipes done, now they are at the cerakote painter and apparently the rest of the parts will get painted this weekend! This project has taken a lot longer than originally thought but everyone gets busy I suppose! The bike is a bit dusty but hopefully soon enough itll be complete!
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 15 Aug 2018 19:57 #788980

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Zack attack from Unit 6 got the basecoat done today! Its so exciting to see everything coming together :)
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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