1976 KZ400-S2 Cafe/Brat

Working on taking this abused KZ400 to a better state! Progress may be slow since this is my first build and as you all know, sometimes parts are scarce. The PO did the awful paint job, all of which will be removed eventually. Right now it doesn't run, engine is not seized and seems to have decent compression (still need to check), I've replaced spark plugs, plug caps and also fashioned up some new air duct boots. Oh and I removed the rear fender because it was bent up real bad and mounted terribly.








Progress Update #1 - Carbs/Petcock
Last night I just finished up COMPLETELY dissembling the carbs, I mean every single last O-ring and screw has been taken out. Next I have to strip the awful red paint, clean, replace worn O-rings, and hopefully get put back together in a timely fashion. I also have the petcock pulled off and I already stripped the paint from it. This thing had a good amount of junk in it :S but I'll be replacing all seals and that home-brew looking screen. I'll continue to update this post as I continue along. For those interested, after the carbs I plan on checking out the condition of the starter and getting the points set and HOPEFULLY going to be able to get this thing started.

There's two things people should need a license for:

1 ) spray paint

B ) JB Weld

Good luck. I bought a couple spray-bomb specials...never again.

Haha couldn't be more true. And yeah this project will be a pain and very time consuming but it is oh so satisfying seeing that original metal underneath

With all that gunk in the petcock, how does the inside of your fuel tank look like ?,

Haven't gotten to the tank yet, it could be quite scary. This bike sat in a barn for a good number of years so it's sure to have some junk in there.

I highly recommend you add an inline fuel filter and put on a new fuel supply line before you hook the carbs back up to the tank. Even if you meticulously clean the tank a little, itty bit of junk hiding in a corner may make its way down into your nice clean carbs and foul them, and that would require you to clean them again (and again). Ed

Yep I'm definitely going to add one in. This is such a meticulous task that the longer I can go without having to do it again, the better

Nice job. It feels good to bring them back, doesn't it?

Oh its absolutely great! Got the paint all removed and taking them in for a ultrasonic cleaning this morning. By the way GPZ I remembered you mentioned you get your jets on power-barn and I went to look last night and was having a difficult time figuring out which ones fit my bike. I've got the CVB36 carb and I need a pilot jet, do you know the part number on power-barn?

ZeffRides wrote: By the way GPZ I remembered you mentioned you get your jets on power-barn and I went to look last night and was having a difficult time figuring out which ones fit my bike. I've got the CVB36 carb and I need a pilot jet, do you know the part number on power-barn?

No sorry. I checked my notes and I only got the main jets from PowerBarn.

Ah okay, thanks anyways.

If it's just clogged, I use a set of micro drill bits or a torch tip cleaner to clean them out.