kz 400 build

Discussion in 'Some Assembly Required' started by sensei, Jul 13, 2012.

  1. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    this 1976 kz 400 build started as a clean up and assemble prodject for a friend but turned into a full on custom build.
    Please let me know your thoughts on it!!!
    #1
  2. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    here it is striped of all extra brackets and refabed the rear part of the frame for seat. then i painted frame with satin black, got new tires, and cleaned up wheels.


    [​IMG]
    #2
  3. RBnite

    RBnite Been here awhile

    Joined:
    Feb 28, 2012
    Oddometer:
    182
    Location:
    Down by the river
    Don't stop now!!!:clap:clap
    #3
  4. Unstable Rider

    Unstable Rider Moto Fotografist

    Joined:
    Jul 23, 2010
    Oddometer:
    2,711
    Location:
    Minn.
    friend of mine had one in 1976-77. it was bad ass in its day, rather snappy n light.

    digging the classy lines of that frame.
    #4
  5. pennswoodsed

    pennswoodsed lizards,bugs and me

    Joined:
    Jan 20, 2007
    Oddometer:
    799
    Location:
    Reading,Pa
    Mine was the maybe most reliable ,brush the snow(yes,snow) off and go bike I ever had.
    Regards,Ed
    #5
  6. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Next was to build the seat pan and put the tank on but the original tank had a hole so insted of fixing it i said to myself, "hey you should build a custom aluminum tank!" WHAT AN IDEAH!!!! haha it took me about three months (of part time hr by hr work) but i got it.

    this was my first design but i didnt like it
    [​IMG]


    This was the design i went with. plus my fabd seat pan.
    [​IMG]
    #6
  7. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    the tank finally got finished and polished! then was to clean up the motor and mount it. plus rear suspension.

    [​IMG]
    #7
  8. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Next i built the header.

    [​IMG]

    Wrapped the header and exhaust tip

    [​IMG]


    Then i built custom polished aluminum carb manifolds.

    [​IMG]
    #8
  9. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    to come...... Clip-ons, seat, electrical, and then hopefully.... RIDEING!!!!! The best part!

    updates coming soon.
    #9
  10. jordan325ic

    jordan325ic Been here awhile

    Joined:
    Mar 21, 2010
    Oddometer:
    271
    Location:
    Dakar, Senegal
    My '79 kz400 is my daily rider, but it's decked out towards the other end of the spectrum decked out with luggage rack, saddlebags, engine guards, etc. Judging by the front drum brake you've got the stripped down kz400 "special" there, which were $995 new from the dealers. My friend's dad bought same year same model new when he went to college and he still remembers how crazy cheap that was for what you got. And, they were made in America.

    The z400s was billed as the ultimate commuter bike back in the day... which roughly translates to "really boring". On the plus side nobody will cry over as they get chopped/cafed by the hundreds.

    Yours looks really good! How long did it take you to make that tank? Are you going to paint it or leave it bare?
    #10
  11. Zecatfish

    Zecatfish XTique Rider

    Joined:
    Dec 30, 2006
    Oddometer:
    7,927
    Location:
    Arkansas USA
    I rode a KZ400 in high school till a kid in a Toyota 4x4 turned left into my lane in front of me. Picture my flying, collapsed the tank with my knees. It caught fire and burned to a crisp. :cry
    It was reliable, SLOW, but fun to ride. Buddies Suzuki 250 would out run it.....
    I preferred the ring a ding of the RD variants I rode better.
    Peppy is not a work that should ever be used in conjunction with the KZ400. :lol3
    Good Luck with your build.
    #11
  12. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Here are my clip-ons i made

    [​IMG]


    Here's my seat i had made

    [​IMG]
    #12
  13. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Things are takeing shape!!!! :evil

    [​IMG]

    [​IMG]

    Just have electrical left to do
    #13
  14. bk brkr baker

    bk brkr baker Long timer

    Joined:
    Jul 19, 2006
    Oddometer:
    6,066
    Location:
    The Bluegrass
    Looking good !

    Uh, it may be a slip of the typeing finger , but, the handle bars you made are more commonly referred to as "Clip-ons".
    Also you may want to build a set with some down-ward angle to them . You'll find it more comfortable.

    Try this. Stand with your hands to the sides. Bring your arms forward. Notice that the hands are at an angle , not flat.
    That seat looks great ! Surley not your first rodeo ?
    #14
  15. JerryH

    JerryH Banned

    Joined:
    Jul 4, 2009
    Oddometer:
    5,069
    Location:
    Chandler, AZ
    I love the way it looks, but those velocity stacks and that open exhaust are well beyond the carbs tunable range. I hope you only plan on using it for short rides.

    I never had a KZ400, but I did have a KZ440. Belt drive. Only problem I ever had with it was starters didn't last
    #15
  16. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope

    no velocity stacks yet, just open throat on the carbs right now. (still need to buy air cleaners.)
    the exhaust tip is just temporary. (i just wanna see what it sounds like when i fire it up for the first time since the build)
    #16
  17. VxZeroKnots

    VxZeroKnots Long timer

    Joined:
    Jun 5, 2008
    Oddometer:
    2,966
    Location:
    Durango CO
    looking amazing man, it's sweet to see another builder on the western slope.

    Maybe try lollipop baffles in the exhaust for back pressure, and pod filters. That setup ended up being jetted really close with my project at this altitude.

    You have skills.
    #17
  18. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Here are my new taillights with the mounts I made.

    [​IMG]

    [​IMG]
    #18
  19. Mechanista

    Mechanista manic depressive

    Joined:
    May 19, 2004
    Oddometer:
    467
    Location:
    G.J. Colo.
    Are those the dual element bulbs (1157)?
    #19
  20. sensei

    sensei ..........

    Joined:
    Sep 14, 2006
    Oddometer:
    45
    Location:
    colorado,western slope
    Yuppers!!!
    #20