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Hello Jack_Mills
Remove the rotor and check the starter clutch parts and do a better cleaning inside the engine case.
A lot of junk and rust parts are left and will destroy the oil pump, bearings and other engine parts.
Not only Show and shine outside. The inside of an engine is more important to do a perfect rebuilt IMO.
The broken starter chain was the beginning of more Problems to come for.....

Nice looking bike. To bad the mechanics couldn't of been gone thru before all the aesthetics.
But that seems to be typical for today. People watching the tv thinking that's the way to go.
Pretty will not get you home.


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I did address the starter chain issue months ago. The chain was within specs (although at the very edge of too loose). The problem is solved with a 24$ nos part. Lucky for me, no other damage happened.

I came here referred by a friend, because of the reputation of the old timers and Kawi bike guru's knowledge who have posted here over the years. Ive donated to the site, Paypal'd others for info and help. Maybe Rex should take some of his own advice and stop assuming before he makes another negative post. If you dont like what you see, you can just scroll to the next thread.

Here are a few more pics of the white pin stripes on the parts.

Sorry Jack_Mills but you last post makes me speechless.
Constructive criticism is like a kind of advise and not to blame you or your work you have done.
I was expecting an more positive answer, like "yes you are right....."

That area of the motor gets a little motor oil because the starter clutch needs it. It's not a lot, but mostly splash through that lower opening under the crank. If that rust starts contaminating the oil it can start to shorten the life of the motor. Nobody wants to see you have to replace bearings and rings.

Moving forward, disregarding rude projecting people thinking down on others. I am not retarded.

So Ive fixed the starter chain, and the paint is finally done. Started her up yesterday for the first time in 18 years or so. Super excited, and very proud of this little 400 project. Got the carbs tuned in and its purring like a cat. Very happy with it, and we're almost done! Im heading to the shop now to put the saddlebags and front fairing on.

Got some more stuff completed today. It should be finished tomorrow. Going to take her out Friday to a show, cant wait to ride!

That's one sharp looking 400 you got there. Good work.

So I was having some problems with my points, and did some searching here, found a thread about Charlies out in Cali. He set me up with an electronic Ignition. I did see that the 81-83 kz440s had a decent EI also. I spoke w the guys at Z1 and they also suggested Charlies. A bit on the expensive side, but what isnt on these old metric bikes. Should have it installed today, and riding tonight!

What have you decided about the lids for the bags?

Had the bike out for a bit today, shes running great! Speedo is acting up, I kinda figured Id have some issues (gear in front wheel was pretty worn) - other than that I am very happy with it. Got a lot of compliments. Lots of guys said "My first bike was a z400" They couldnt get over the "chips" faring n bags on such a small bike. Most didnt know about the 77 A1/78A2. Its a bit loud but we figured that. It really is running strong. I want to extend my sincere thanks to everyone who has offered advice, help and comments to help this dream of restoring this bike become reality. Much appreciated.

One thing that is still bugging me is the flashing brake stop light on the tach from putting LED 1157 bulb in tail light. Ive tried a few things that were mentioned here but nothing seems to get it to stop flashing. If anyone has any more input about it, I would be thankful for that. If I cant figure it out, Ill prob just run a new circuit.

Thanks again everyone!