TOPIC:

here's my new bike, a 79 KZ400 that came as a frame and 6 boxes of parts. PO supplied a work table and a clymer's too. progress is ok so far, have a rolling chassis with brakes. next up is engine reassembly, am hoping for a spring start-up and ride.

Welcome to KZR noman!
Patton has written up an excellent thread about posting pics here: www.kzrider.com/forum/8-about-the-site/5...posting-pics-is-easy
Looking forward to seeing your bike.
Bill

thx, bill. attachments added to original post. the drop and drag feature is very handy.

the rolling chassis pic was late fall, since then i've refurb'd the front wheel (full disass and clean, polish spokes, bearing check/relube) and front brake ( full disass of caliper and master, pistons and bores polished, reass. and bleed). am currently into a deep dive on the real wheel. bearings checked/relubed, carrier polished and cush drive checked, full disass of brake panel to polish exterior and pins,
new pads, etc. only have 20 more spokes to polish, out of 36.

It looks like the front fork axle clamps have been tightened wrong. There should be zero gap at the front and a gap at the back. Take a look at the Kawasaki Service Manual as it is very specific about this issue and warns about problems if the clamps are not tightened properly. Ed

i wrote a really long reply but it disappeared, short story: this isn't final assembly, just a rolling chassis. final assembly will occur after: engine is reassembled and installed, wiring component tabs placed, brake pivot welded back on. then all will be removed for final painting. PO de-tab'd the frame bikes, some need to be installed. am familiar with the "F" orientation, similar to early hondas w/showa (i think) forks.

Welcome!

rear wheel assy serviced and polished, w/new sprocket. cleaned cases until they were spotless inside/out and plopped in the trans and crank. each of these critical steps took awhile, as i read the clymer's, service manual and read posts on this site for days before assy.
everything turns smoothly, shifts fine. still waiting on the pushrod seal.

That's an unusual arrangement on the lower rear shock mount. Is there a reason that extra piece was added? It seems like it would allow the frame to move left and right relative to the rear tire more than the normal setup. Ed

Nice catch, Ed. That seems especially unexpected considering the shocks appear to be adjustable for length.

Yeah that is different. Those look like YSS shocks if they are they are adjustable to just over an inch longer. I wouldn't trust that setup and it will have negative effects on handling.

those new adjustable shocks were in the pile of free parts i got w/the bike, they're made by NCT. when installed without the bracketry seen and adjusted fully "compressed", there was no clearance to the drive chain. knowing some manufacturers allow gas shocks to be oriented upside-down i tried fitting them this way, w/out success.

i elected to try adding the included brackets first, before replacing the shocks. the lowest bracket is held side-to-side as is normally done, by the swingarm mount. front-to-rear bracket stability is by the use of a tight shim, held in place by the tightened bolt.

everything there is torqued,but i feel there is still opportunity for some flex at that location due to the bracket "ears", and inherent clearances seen between the holes and bolts. also in the pile were some used shocks from a '78 KZ400, but oil mist is seen around the seal, and and the manual says there not rebuildable. pretty sure am looking to replace this set-up, but it will be fine for rolling the bike around the "shop" and for test rides this spring.

you also may have noted the lack of the original tab-style locks for the sprocket bolt nuts . they were missing so i substituted split lock style washers combined with loctite 242 and properly torqued fasteners. like the front axle clamp nuts.

and many thx for the kind observations.
bob p

some progress. cases were assembled and engine plopped into the frame as-is, to reduce scratches. throughout the assembly i checked the kickstarter, gearing, and shifting multiple times, but won't know for sure until the test ride next spring. starter planetary gearset, oil pump, oil strainer, etc were also cleaned, relubed and installed. next up is the clutch release assy, and polishing the last two cases. found a Z1 enterprises stainless steel bolt set in the bottom of one of the tubs, and they're looking nice.