adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Jan 27, 2024 15:39:17 GMT
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Thanks Aha yes I did see that, I only recently got watching his videos as a couple of them got recommended to me on Youtube, then lo and behold a KZ400 vid appears Those silencers do look quite nice. I've not looked too much into exhaust options at the moment, my vague idea is to have some typical reverse cone silencers, bit louder than stock naturally, but getting the length right is important to the look for me. Little shorty exhausts just don't look right in my eyes
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Davey
Posted a lot
Resident Tyre Nerd.
Posts: 2,197
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K11 Micra x3 - Mk3 astra - Seat Marbella - Mk6 Escort estate - B5 Passat - Alfa 156 estate - E36 compact Mk2 MR2 T-bar - E46 328i - Skoda Superb - Fiat seicento - 6n2 Polo - 6n polo 1.6 - Mk1 GS300 EU8 civic type S - MG ZT cdti - R56 MINI Cooper S - Audi A3 8p - Jaguar XF (X250) - FN2 Civic Type R - Mk2 2.0i Ford Focus
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Feb 15, 2024 18:35:27 GMT
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Sadly no, work has been crazy and leaving me drained of energy in the evenings so I've not been able to get out as much as I'd like. The throttle cable ends are a bit different to what I had on the top of the Mikunis so I need to work out how to make them work with each other. I'm a Mikuni novice so got a bit stuck there! I did however fit a subtly period correct numberplate from the always excellent RetroPlates on Instagram Adn tarted up the old plastic chain guard using JD Weld to fill some of the cracks and a spray over with some gloss black. It'll do for now A semi-free weekend and I will be back on this though!
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Feb 25, 2024 21:18:56 GMT
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I had a free weekend so I've done a bit more on the bike, made some good progress. First off I got the multimeter out and poked around the original ignition coil and regulator rectifier, the readings I was getting were suggesting that trying to cheap out by using the original items would be a false economy so I got on Wemoto and ordered a few bits. In addition to the coil and regulator rectifier, I got a new bleed screw for the front caliper as everytime I went to the bike, there seemed to be some fluid around the screw, as well as a new clutch cable as although the original did move freely, the outer was very crispy and the adjuster locked solid. Getting the coil and reg/rec fitted up was straightforward, got the HT leads all connected up to the plugs too The clutch cable was a bit of a headscratcher as I just couldn't seem to be able to get the right adjustment length set up. I then remembered that I'd printed out a section from the Kawasaki workshop manual on setting up the cable, followed the steps and got it set up with just the right amount of freeplay at the lever. The new bleed screw seems to have stopped any leaking, so I went ahead and bled the front brake, which is another thing off the list. I did also make some progress with routing and connecting up the wiring loom, it's fairly self-explanatory really but I have been referring to old photos to help with getting the routing right etc. I did find one wire that goes to the ignition switch that has a bit of damage As it's quite near the plug, I'm going to try and de-pin it and repair it before re-installing into the plug. I've also just received some loom tape as the original PVC sleeving has gone brittle where the UV has baked it, particularly in the looms that go to the handlebar controls. So I'll tidy that up before everything is in it's final routing. I've also ordered some bits for the carbs which should mean I can connect up the throttle cables. At that point it'll just be connect up the battery and make sure all the wiring is happy, set the static ignition timing, put something flammable in the carbs and see what happens... Also only a week or two away from when the painted bits should be done so it's all coming together
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Mar 12, 2024 22:12:35 GMT
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Not quite the big "it's running" update, but there's been things happening. Firstly, been tidying up some bits of loom using loom tape, not taken any pics but it looks much nicer. I made a repair on that bit of wire that was partially cut in my last update, managed to de-pin it from the plug, bought some connectors but they weren't quite the same size so ended up soldering on a new bit of wire to the old pin, it's all back together and seems to be OK Got some nice air filters from DNA which fit perfectly There have been some frustrations though, I've still not been able to get the throttle cable connected up to the Mikunis. Bought some bits that I thought would sort it but they don't quite work where the cable goes through the cap of the carb, but I'll find a solution. I was trying the clutch lever a few times the other day when there was a "twang" and the lever went slack. So I need to get the cover off again and re-adjust the cable which is annoying. Also today I thought I saw the front caliper bleed nipple was leaking again. I've cleaned it off and double checked it's tight so will monitor it. However in more positive news, having connected up a load of the loom at the front of the bike now, I thought why not hook up the battery and see what happens.. We have life, and more importantly, no smoke or fire Headlight works on lo and hi, tail light works, brake light works off both lever and pedal, tell tale lights seem to work, and the big one is that it cranks on the starter motor nicely too There are a couple of bits that need some attention though, the horn doesn't work, and I don't seem to have any indicators but it shouldn't be hard to trace the source of the issues there. Lastly I checked in with the paint guy, the tank and panels are in primer and due for paint this week I believe so hopefully should have those back soon!
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Davey
Posted a lot
Resident Tyre Nerd.
Posts: 2,197
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Mar 13, 2024 12:12:54 GMT
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So close!
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K11 Micra x3 - Mk3 astra - Seat Marbella - Mk6 Escort estate - B5 Passat - Alfa 156 estate - E36 compact Mk2 MR2 T-bar - E46 328i - Skoda Superb - Fiat seicento - 6n2 Polo - 6n polo 1.6 - Mk1 GS300 EU8 civic type S - MG ZT cdti - R56 MINI Cooper S - Audi A3 8p - Jaguar XF (X250) - FN2 Civic Type R - Mk2 2.0i Ford Focus
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Mar 13, 2024 22:36:30 GMT
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No cigar...
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Still learning...still spending...still breaking things!
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Mar 25, 2024 18:39:41 GMT
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We're still not running yet, I'm being very patient but I have some throttle cable fittings coming, as well as some recommended jet sizes as well which should hopefully reduce the amount of tuning needed once it is running. I have made progress on the electrical gremlins though. As the horn and indicators both weren't working, and are controlled by the same switchgear, I initially thought that was the culprit. So I took it off, cleaned up the connectors, did a bit of continuity testing to make sure everything was doing what it should. No change. I was mainly focused on the indicators, so I was checking and re-checking the connections were all good. Tried a couple of different flasher relays. The KZ400 originally had an indicator buzzer, bit of a novelty on a bike and many removed them as they were annoying, mine was missing so I tried bridging the terminals in the connector, still no dice. The odd thing was that the wiring diagram for the bike, showed the front indicators as having three connections, two powers and an earth, but there are only two wires going to each indicator. The indicators are bolted to metal brackets which are on the forks, but they're also rubber insulated. Touched a wire from the body of the indicator to part of the frame and got a flash of light the indicators had no earths. Moved a couple of wires around up front and got this It has ocurred to me since that having US style amber marker lights, might not be the best idea so I'll see if I can set them up in a more European fashion.. No flashing though and no rear indicators in that photo either. So the next day I had a look at the rears, the short version is that I faffed around a bit with them but ultimately it was an earthing issue again. Partly due to the elaborate internal connection between the bulb holder and the indicator housing having some corrosion in it which can't have been helping the connection And partly because when I refurbed the rear bracket that holds the indicators and the tailight, I painted over the interface where the indicators fit on, took a bit of that paint off and there was light They even slowly flash now with both front and rear indicators lit up. With the engine running there would be a bit more juice and they should flash more quickly I think. The horn turned out to be duff. Connected it direct to the battery and not a peep. Pulled one of the horns off the Crossfire, plugged it into the loom and horn was working on the button so that is an easy fix, ordered a suitable horn off ebay. With those two bits fixed, I can finalise the loom routing with cable ties, and get the headlight fitted. Other than that I'm twiddling my thumbs until my tank and carb bits turn up. I suppose I'd better order some fuel hose actually...
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Mar 25, 2024 20:14:22 GMT
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Great progress.
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Still learning...still spending...still breaking things!
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waynedear
Posted a lot
Posts: 1,369
Member is Online
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I do admire your dedication to the task. I have done 2 full restorations, KH400, RD400e, when the engines start and you get to ride them it is fantastic. 👍
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Bicycle x1 Alfa Giulietta (now wife's) Alfa 156 BMW 630i Honda rc36
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Davey
Posted a lot
Resident Tyre Nerd.
Posts: 2,197
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I haven't been this invested in a first start in a while. Stop with the cliff-hangers already!
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K11 Micra x3 - Mk3 astra - Seat Marbella - Mk6 Escort estate - B5 Passat - Alfa 156 estate - E36 compact Mk2 MR2 T-bar - E46 328i - Skoda Superb - Fiat seicento - 6n2 Polo - 6n polo 1.6 - Mk1 GS300 EU8 civic type S - MG ZT cdti - R56 MINI Cooper S - Audi A3 8p - Jaguar XF (X250) - FN2 Civic Type R - Mk2 2.0i Ford Focus
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Mar 26, 2024 18:03:29 GMT
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Thanks guys 😁 haha I'm not trying to drag it out intentionally 😂 I will make sure I video the first start though
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bstardchild
Club Retro Rides Member
Posts: 14,886
Club RR Member Number: 71
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Apr 13, 2024 15:45:17 GMT
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You’re making more progress than I am with getting this back on the road There is another GPz behind it that I need to do next Both need to be sold this spring cos I’ve run out of space and number of motorcycles exceeds what I can keep warm and dry over winter
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Apr 16, 2024 11:08:21 GMT
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Awaiting the fire up!
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adam73bgt
Club Retro Rides Member
Posts: 4,865
Club RR Member Number: 58
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Apr 16, 2024 12:11:59 GMT
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Nice bstardchild ! A gpz1000rx? I must confess I'm not all that clued up on 80s kawasakis or 80s bikes in general but an 80s bike is on the mental wishlist for the future I was hoping to make my next post here the big fire up flyingphil but alas I'm waiting on parts again 🙃 An update since last time though, horn arrived, got fitted so that's all good. Unplugged the US spec indicator DRL's as I think it will make the indicators less obvious, and I've pretty much routed all the wiring now. My carb guy sent over some recommended jet sizes for vm28s on a kz400, so I had the carbs off to swap those over, but due to a bit of miscommunication he didn't send the bits I need to connect the throttle cables up so I'm waiting on those now. The big exciting news is that I got my painted parts back and they look incredible. My phone camera doesn't do them justice but they're a deep candy blue with silver pinstripes, I'm very happy with them I very carefully then reattached the tank and side panel badges, tank badges easily screw on. The side panel badges needed a little restoration with white and silver paint pens, the plastic prongs on the badges were intact so I used the original style clips which were a bit of a pain, but got there in the end using a flat head screwdriver to push the clip on while I rested the side panel on a towel. And I couldn't not fit up all the panels to see how it would look 😏 Next update will be trying to start the damn thing!
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Davey
Posted a lot
Resident Tyre Nerd.
Posts: 2,197
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Apr 16, 2024 15:21:21 GMT
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Hot damn that's shiny.
Great job.
Now brum brum noises.
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K11 Micra x3 - Mk3 astra - Seat Marbella - Mk6 Escort estate - B5 Passat - Alfa 156 estate - E36 compact Mk2 MR2 T-bar - E46 328i - Skoda Superb - Fiat seicento - 6n2 Polo - 6n polo 1.6 - Mk1 GS300 EU8 civic type S - MG ZT cdti - R56 MINI Cooper S - Audi A3 8p - Jaguar XF (X250) - FN2 Civic Type R - Mk2 2.0i Ford Focus
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Apr 16, 2024 15:26:24 GMT
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Nice shiny parts! It is looking really good...now to see if it sounds and goes well!!
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Apr 16, 2024 20:25:07 GMT
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Oh, that looks the business, really like the blue too. Great stuff.
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Still learning...still spending...still breaking things!
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bstardchild
Club Retro Rides Member
Posts: 14,886
Club RR Member Number: 71
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Apr 16, 2024 23:03:11 GMT
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That paintwork is really nice - nice subtle flake - great colour too
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generallee
Posted a lot
Posts: 1,008
Member is Online
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Apr 18, 2024 10:17:08 GMT
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I'm not into motorbikes at all, but have really enjoyed this. Looks great!
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