New Beginning

March 4, 2018

The engine is back in frame! Great success. I must say, though, it was a tough job, got a few scratches on the frame in the process. But hey, we’re moving forward now. Next, get the coil, carbs, exhaust, some electrical and try to get it started.

March 5, 2018

Got the new coil sorted out. Another hour spent on cleaning the damn stator. Rusty and dirty, and as usual i should have done all this stuff before beginning the rebuild.

March 6, 2018

Almost done with the stator, the store didn’t carry the screw i needed (M5x8) so i’ll have another good source of metric bots. Checked the resistance - all in spec.

Started on carbs. These Mikunis VM32 were not that bad, just dirty outside, insides looked pretty clean.

March 7, 2018

Finished with the stator, new gasket and bolts. Carbs are clenead and installed. Just need to get a new hose clamps, the old ones look junky. Also, i bought a set of new control switches, they are a direct fitment over the original ones.

March 11, 2018

Small progress today: cleaned up and fitted the exhaust headers. These are off eBay. I’m thinking to go 2-into-2 setup, the previous owner had 2-into-1 MAC exhaust, which i might still use if i dont find a pair of good short mufflers. Started on brake lines and switch, it was nasty.

March 14, 2018

Cleaned and stripped paint from the master cylinder. It did not look great so i decided to paint it. Started planning on control cluster, will need to fabricate the ignition mount somehow, this should be fun. Cut open the wiring harness. Oh man, i dont know what to say, getting it in the good should will definitely be challenging.

March 18, 2018

Decided to paint the master cylinder. Also rebuilt brake caliper is back on the bike.

March 19, 2018

Mufflers, front fender and carb filters have arrived. These mufflers are nice, a direct slip on, however i learned that one of my exhaust headers is a bit bent, will have to figure out how to make it even with the second one. The front fender i ordered if off from 1979 kz400 instead of 1975, so the mount bracket is shorter and also riveted onto the fender. Had to drind those rivets down. Bolt holes still fit with my old braket so that’s good news.

March 20, 2018

Didn’t do anything today. Just a pic of a painted master cylinder.

March 21, 2018

Got new control switches installed. These are niiiice, almost exact replica. Other than that did a bunch of small stuff, synced carbs, etc.

March 25, 2018

Adjusted valves. Kind of hard to do with the way how the valve adjuster screws are setup. Will have to do that again after i fire her up. Put the oil in, checked clutch, Getting the electrical setup to get everything going. Exciting times. Also, some of the valve caps are messed up, need to get a replacement.

March 28, 2018

Today is the day! She’s alive. I finally did it. Put some fuel in, pressed the start button and she started right up. I’m excited!

April 1, 2018

Not much progress today. So the fender mud guard that i bought some time ago did not come off of 1975 kz400, but from 1977. Turned out the shape and mount holes are completely different. I decided to cut it a bit and make it work with existing mount points. Fixed for now. Oh and i have to paint the fender soon. Also working through getting the rear light back on: the stop signal and blinkers.

April 3, 2018

Got new valve caps on, these are huge comparing to the old ones. Messing with electrical setup. I’ve got Rick’s regulator/rectifier combo but before i chop the old setup just need to make sure all charging system components are actually working. Tried new mufflers on, what a nice growl. Also, the parts bin is almost empty!

April 4, 2018

Got the battery box back on the bike. That thing is wicked. I might make a new box after i finish the build, but for now it’ll do. Mufflers are back, adjusted the carbs and idle, all good there. New mufflers are real nice but it looks like the left one is a bit longer and has it’s throat angled a bit different. Fuck it, im fine with that for now.

April 7, 2018

More work on electrical. Fitting the new tail light, looks nice, although im not sure about the lenth of the rear fender. Cut it or not? Not sure. I’m getting closer and closer to the finish line.

April 8, 2018

Sorted out all electical stuff, need to get the new gauges hooked up next time. Was cleaning up the front fender (too much rust) and fitting the new headlight bucket and gauges. This one is pretty bright although i need to figure out the deal with the new headlight bracket. It does not have any mount points for turn signals. Other misc stuff. Slow and steady progress.

April 8, 2018

Welp, the paint color for the side covers is definitely not the “charcoal metallic”, it has some green to it. This is the second time i picked up the wrong can.. Maybe i’ll just go with black. Drilled the mount points for the turn signals, i think it’ll work fine. Labeled all the electrical, ran a quick electrical test on the new controls and tach gauges, they look great with the backlight. Everything works so far.

April 21, 2018

Chopped the rear fender and getting ready to paint the front fender. Had to clean it up with a wire wheel and sand down all the rust spots. Also, the engine does not run well on the left cylinder and developed some leaks…

April 22, 2018

More fucking around today. The engine is leaking, this sucks. Found two small leaks from the valve cover and another one somewhere in the head, could not locate it yet.

April 28, 2018

Finished the front fender and rear fender/lights. Freshened up a few connectors that were either burned or corroded. I feel like i’m getting closer and closer to the finish line, althought still need to sort our a few things like engine leaks. Tried my hand at making a custom ignition switch bracket. We’ll see how it comes out.

May 1, 2018

More of wiring nonsence.

May 8, 2018.

Wiring was done, forgot to take the pictures. Opened up the head cover that was leaking some oil. Applied some silicone to the o-ring to make sure it seals alright, also retorqued the head. Getting tired of this project..

May 9, 2018

Patched up cracked clutch cover with JB Weld. Installed the new gas cap, started on side covers, they’ll need a fresh coat of paint. Finished with ignition switch fabrication.