1976 KZ400 D3 Restore Project

As promised some pics form the valve seal pusher( for 7,00 and 8,00 mm valve stem ).
It will took some time to upload, have poor Internet speed. My ISP fu**ed my port repair.

The valve stem condom thing. The red once are for 6,00 mm valve stems (16 valve engine)
I show the drink straw method with BMW valve stem seals.







Michael

Have any of yinz ever painted/powdered the plastic piece of the top of the 400 carbs? Or have you powdered the top and baked at 400 and the plastic piece didn’t melt?

Well this new illusion powder is tits! and you can put the top of the carbs in and the plastic piece does not melt

Hey All,

I just wanted to let you know that I bought Kawi # 44025-003 Plunger Piston rings for my 76 front shocks off of ebay, and they were not the proper ones, even though the seller claimed they are. Notice the thickness difference between the original (right) and the new one (left). Luckily the old ones were not in bad shape so I reused them and rebuilt the front shocks yesterday and they are holding up strong. I did notice from some old posts that users mentioned 5oz of fork oil per side (417 -500 mm from top of fork), but I feel this number is not correct. We ended up putting about 7oz of fork oil in each side and it seems to be the sweet spot. The sludge I took out of these forks looked like clay almost...

Finally getting around to replacing the valve stem seals tonight. Life got super busy for a while, so its nice to spend some time on the bike projects. Lots of polishing on the motor to do yet also.

Hello Guru's!

Long time no posting. Life gets busy. So Im making some headway on this project and I ordered some new o rings and gaskets and what not. In the attached photo there are 2 identical parts that were not on the motor to begin with. Part #4 on this photo. Cylinder Damper Rubber. Do these go in the holes in the bottom that the bolt in front of the spark plug goes? Thanks!

According to Kawasaki, that is part 92075-256 which is most likely a cylinder cooling-fin damper. Note there should be a quantity of 12 of them on the bike. They go in between cylinder fins to reduce ringing noise of the fins.

www.kawasaki.com/Parts/PartsDiagram/142718/1976/KZ400-D3

They usually are little bits of black rubber. I don't know why the photo looks so brownish, unless that is a coating of some sort.

Ah that makes total sense! I bought 2, thinking they went in the bottom of the holes for the bolts that go in front of the spark plugs...probably paid too much

I was also missing the o rings that go on the bottom of the cylinders. Thank you very much for your time and input. Ive been cleaning, sanding, and polishing for days. I wish I knew someone who did vapor blasting close to Pittsburgh. That matte finish is so niceeeeee!

Jack_Mills wrote: I wish I knew someone who did vapor blasting close to Pittsburgh.

Not super close (about 2 hours NW), but I found this site a while back.

www.arnoldsdesign.com/Vapor-Blasting.html

I've never contacted them, but the pics look good.

I reached out to Arnolds Design...

85$ per case half
Cylinder block $75
Twin head $75
Head Cover 30$
Small caps 3.50
Carbs 50$ each
Side covers 15-40$ each.

Hes very expensive. Sigh...