TOPIC:

I have a bit of problem, I have brought a Z400-J2 which is a four cylinder, they made the J1,J2,J3 for the European market. My problem is that cylinder number #1 is seized and when it was stored the previous owner had left the spark plug out, resulting in the piston seizing in the cylinder, I have a funny feeling I'm going to need a new set of cylinder and a piston and rings, only problem is i cant find any part numbers. 

Does anyone have a printout or is willing to scan the parts catalouge, or know if what parts I need? 
I can only see 4 + on the inside on one side and 1227 with possibly a 0 or o beforehand but it just looks like a casting mark if that helps.


Many Thanks 

Here are a few parts, but none of what you need now. 

www.louis.eu/en/bike-database/kawasaki-z...me_asc&viewMode=grid

What condition is the cylinder in ? if you can get away with honing then IMD do a ring set for it - oversized pistons seem tricky to find !

 

There's a microfiche available on EB out of Germany.   Item #354035198533 - click!   Some libraries may still have readers available.
EB search = Z400J microfiche.

Several Z400J parts catalogs are listed on EB from France or Italy.

Several used cylinder blocks are on EB out of Germany and there's a set of 3 NOS pistons from Italy (kind of expensive).

Cmsnl.com (UK) has diagrams for some Euro models, but I didn't see the Z400J. The later ZR400 diagrams are available, but I don't know if they'd do you any good. Cmsnl has a cross-reference, so I checked the ZR400 cylinder base gasket & piston, but the 400J wasn't listed. You have to sign in to see all of the models that use the same part.

 

Not sure this will help you at all.  I was able to find a parts list of sorts. It does not include any actual part numbers rather just the diagrams for the parts with reference numbers but no part numbers. Any way here you go.

OK one of the sites selling a part catalogue happened to show a page which shows part numbers for standard, and both next over bore sizes . It also shows part numbers for the 3 different ring sets. 

13001-1029 piston standard
13029-1011 piston .020 oversize
13027-1012 piston .040 oversize

Here is the ebay site  ebay  de  itm/394763403810
Here is a copy of the page in question.

There's a NOS standard piston 13001-1029 listed on EB from the UK. ~$78.

Thank you for everyone'ss replies. I took another stab at the ye old cylinders today and managed to get the stuck piston out. It definitely needed some persuading for sure! Heat, penetrating spray, vingar and lotttssss more heat along with an almighty wack with a hammer and a big socket extension and she eventually broke free.

After taking my honing stones to the conflicting cylinder and touching the others up, i have now come to the realisation that that cylindar is as much use as a chocolate fireguard! 
After lots of head scratching and grunting, I have have 4 options. 

Option 1 - Find one NOS standard piston (provided the others clean up okay and I can get the rings out) then install three old pistons and one new piston with a set of new rings for all. Then get another 2nd hand cylinder as the current one is junk as S.T.D size won't fit , then hope the newer cylinders clean up okay (storage marks/ corrosion on pictures) and accept the new NOS standard and older pistons and rings but I can only currently find 2 new standard pistons.  
Option 2 - Get the current cylinder rebored to 0.040 as 0.020 i don't think will be enough as the corrosion is still bad after a heavy hone. Then get 0.040 O/S pistons. which i can find 4 off and a set of 0.040 O/S rings.   
Option 3 - Get the other 2nd had cylinder and rebore that one to 0.040 and slap the new 0.040 O/S pistons and rings in.
Option 4 - Find a 550 engine and relative bits and install that (This would mean it's no longer a true 400J )

I would be glad to hear everyone's thoughts and opinions. 
I think I have got some work cut out for me!! 

 Many Thanks in advance 

Thank you for everyone's replies. I took another stab at the ye old cylinders today and managed to get the stuck piston out. It definitely needed some persuading for sure! Heat, penetrating spray, vingar and lotttssss more heat along with an almighty wack with a hammer and a big socket extension and she eventually broke free.

After taking my honing stones to the conflicting cylinder and touching the others up, i have now come to the realisation that that cylindar is as much use as a chocolate fireguard! 
After lots of head scratching and grunting, I have have 4 options. 

Option 1 - Find one NOS standard piston (provided the others clean up okay and I can get the rings out) then install three old pistons and one new piston with a set of new rings for all. Then get another 2nd hand cylinder as the current one is junk as S.T.D size won't fit , then hope the newer cylinders clean up okay (storage marks/ corrosion on pictures) and accept the new NOS standard and older pistons and rings but I can only currently find 2 new standard pistons.  
Option 2 - Get the current cylinder rebored to 0.040 as 0.020 i don't think will be enough as the corrosion is still bad after a heavy hone. Then get 0.040 O/S pistons. which i can find 4 off and a set of 0.040 O/S rings.   
Option 3 - Get the other 2nd had cylinder and rebore that one to 0.040 and slap the new 0.040 O/S pistons and rings in.
Option 4 - Find a 550 engine and relative bits and install that (This would mean it's no longer a true 400J )

I would be glad to hear everyone's thoughts and opinions. 
I think I have got some work cut out for me!! 

 Many Thanks in advance 

0.04 is 1mm so if the corrosion is less than 0.5mm deep you would be ok (the problem with another block is you can only see so much in a photo so don't really know what you getting) where did you manage to find oversize pistons ?

He sales a lot of KZ 400 J parts bikes

motorradteile-bielefeld.de/foto-galerie-kawasaki/

motorradteile-bielefeld.de/galerie/thumbnails.php?album=1314
motorradteile-bielefeld.de/galerie/thumb...php?album=903&page=1
motorradteile-bielefeld.de/galerie/thumb...php?album=992&page=1