1975 KZ400D - restore project

Great progress. The stator area was the worst I've ever seen. Keep pitching you are winning.

Ok Kawi KZ guru's...I have a question for you. So as you know I have a 77 kz400a1 as a cadaver. We took the front faring, the luggage rack, saddle bags and mufflers from the 77 and are putting them on the 75. I've been using CMSNL and a few other places to buy/view parts and such. The mufflers from the 77 have the tapered ends vs the straight ends from the 75. From all the schematics Ive looked at, I can not find these mufflers (but every 77a1 and 78a2 have said mufflers on them). They are 2 separate mufflers, not 2 into 1. They dont have the cross bar/support under the motor like some do. Unlike the 75 mufflers, the 77a1 mufflers have a rubber grommit that the metal plates attach through. I can not find these grommits anywhere...but I mean I cant find them on any schematics either. Im sure we could make them or cross ref something to work, but I was hoping to get the exact fit grommits, since we are getting the mufflers ceramic coated. Can any of you shoot me a link to a schematic or perhaps you are familiar with what Im speaking and offer any advice? Much Thanks!

Kawasaki and Partzzilla show that mufflers with that mounting system are from the A2. They show the A1 as having a bolt-on triangular bracket. Sadly, no mention of the grommet on either.....

www.kawasaki.com/Parts/PartsDiagram/142560/1977/KZ400-A1

Here is a pic of the mounting hardware before powder, they are the 2 triangle parts in the middle. One of those holes goes a bolt through a grommit and such to hold it into place. Here is a picture of them on a kz 400b i.pinimg.com/736x/74/75/35/74753541e9f90...cars-motorcycles.jpg then after looking at that I went here www.cmsnl.com/kawasaki-kz400b1-1978-cana...t/51466.html#results and it def doesnt have the cross pipe/support pipe as shown in the specs. It is the pipe, just without that cross.

No eBay APP ID and/or Cert ID defined in Kunena configurationHere it is on the same bike I have as a cadaver.

kz400.com/History%20bilder/KZ400%20A%20p...e%20of%20i-1_B_L.jpg
also

I may have answered my own question: www.ebay.com/p/NOS-Kawasaki-Muffler-Fitt...047675.c100005.m1851

..this bike came from a barn just outside Jersey on the PA side of the river. Had Atlantic City Kawi dealer plate and metal emblem on the gastank lid. From what Tim says, it looks like they cut the center cross part off at some point. I liked these exhausts, because they were a bit longer than the 75s (for the sake of the saddlebags)...may have to do some fabrication and welding or use the 75s exhaust. Saga continues haha

After messing around with the exhaust from the 77a1 we’ve decided to make custom mufflers w baffles. Then when I was putting the chain on I noticed there a rubber stopper on the left muffler to stop the center stand...so we are gonna weld a stop on the center stand. Got the front tire mounted, replaced the rusted out front fork top bolts, the carbs from the 77a1 had the rubber plugs, one of the carbs on my 75, the rubber plug fit nice, not the other one...gonna use something here at the shop for that one. I got the specs and still will need 2-4 more for the other bikes. The stator will be back together, along w the sprocket cover and all of that. Soon I will have to start sanding the parts for paint.

Today was a great day working on the 75. Got the carbs remounted, and the drain hoses ran. Got the chain cut down, installed and the rear hub all finished. Got the left footpeg and kickstand back on secure. Tim and I tackled the front brakes and master cylinder. 10x1.25 is the size going into the caliper, parts guy at the store said most auto places dont carry that one, so I had to clean up one from the cadaver. Blake helped me bleed the line, but since it was all dry, we got it feeling decent, but we will run the air bleed machine on it again tomorrow or Friday. No leaks! Since the center stand relies on a rubber bushing coming off the stock mufflers to keep it from springing all the way up and into the chain (Blake is going to make a pair of stainless mufflers w 8 inch baffles), Tim is going to build a stop for it in the next few days. I have a small oil leak from the oil filter, gonna drain the oil tomorrow and pull that back down and see whats going on. All the body parts have been knocked down, and Zack at Unit 6 Motoring is going to start fixing the fiberglass stuff tomorrow and Im gonna try to lend him a hand.

Does anyone know any decent chrome shops in/around Pennsylvania, Ohio, or West Virginia?

Ha Im surprised no one seen that I had the axle bolt in backwards haha, anyways I fixed that, and ordered a new oil filter o ring gasket old one got cut in half somehow, which was the reason for the leak. Front brakes are working and strong. Zack started doing fiberglass work on the parts. Cant wait to see them all painted! Getting really close now..

Worked on the bike a bit today. Figured out where a shoulder part went from taking it off on the 76 the other day. Fixed the oil leak around the filter (bad o ring). Front brakes look all good to go, holding pressure and no leaks! Started rebuilding the turn signals, and got the saddlebag framing and some other odds and ends powdered. Hopefully we will work on the bodywork tomorrow and get the parts primed and ready for paint! I started to sandblast some of the 76 parts, but I broke the blaster again... cant wait to hear her fire up!

Looking really good Jack. I love the black hubs...

Spent most of the evening tonight bolting up the framework for the saddlebags. Also got the rear turn signals mounted and wired up. Too bad the whole frame wasnt tube, not very many options on running the wires. Took the turn signal relay off cause my signals were not working, and it sounds like jumpin beans inside when shaken...the orange lead was rusted out also. The 77 cadaver has a similar one, but its 3x as long. Going to take that one to the shop next time I go and test it out. Ebay ranges from $18/used--60/nos. Also noticed that my brake light is not engaging on the tail light, but lights up on the tach (both front and rear brake tested). I only had the one 1157 bulb, it looked fine. I have a couple laying around here Ill take with me to the shop next I go. Zack from Unit 6 spent several hours this evening doing body work on the parts, another couple hours and they should be ready for primer. I sure do wish someone handy with photoshop could duplicate the under seat stickers and rear inner fender stickers. Reached out to several of the places mentioned here, and that I found online, all saying not a demand for the time, etc. Only see a Japanese sticker set. Another day in the books. Goodnight