I bought the 1977 KZ-400 - Page 3

FastDoc · 03-02-2010, 11:17 PM

Quote:

Originally Posted by SpudRider

Quote:

Originally Posted by FastDoc

I just redid the carbs and intake boots. Thank God I seem to have done it right and she runs great. I think I might be done with the mechanicals!

That is wonderful, Doc! Dare I ask for more photographs?

Spud

My pleasure. The boots that were on it worked only because they were covered in RTV silicone and were ugly. The only internal carb parts i needed to replace were the float needle valves and the float bowl O rings and the fuel line. I got off easy I think. Tomorrow I'll get a new in line fuel filter. Seeing how TINY those internal passages are makes me paranoid of clogging something!

The main good stuff I can't photograph, like how nice it runs not and no longer acts and smells rich.

Top speed did not change, I guess it's an 85 MPH bike which is fine with me, and 15 MPH faster than I need to go on it. I just used top speed as a rough indicator of power output.

I think I'm still down some because when they were new the articles had them clocked at 98, no way mine would do that. But, 33 years ago was a long time!

katoranger · 03-03-2010, 07:53 AM

I had RTV sealed boots on my radian. Did the job.

Also you can make a video for us.

85 on a little bike like that is fast enough.

Reveeen · 03-03-2010, 08:42 AM

This may be of some help:

http://www.kz400.com/index.html

FastDoc · 03-03-2010, 11:26 AM

The KZ400 site was instrumental and helped me with my project very much. 85 is plenty fast, it was just a way to test power output. the bike felt very fine at that speed. I don't have it done. Oh the joys of antique bike repair. this AM there was puddle of gas under left carb drain, the needle valve must be defective, incorrectly installed or some dirt may be in there. Also the vacuum slide diaphrams, while intact, are old, swollen, and balky and will get replaced.

Reveeen · 03-03-2010, 12:43 PM

I have had, well, "reasonable luck" replacing the steel needle valves with viton rubber tip valves stolen out of automotive carb rebuild kits. (otherwise give the needle a rap, on the blunt end, with a gasket hammer)

katoranger · 03-03-2010, 02:44 PM

A friend is sponsored by this Canadian company. He races in the WERA series vintage bikes.

http://www.siriusconinc.com/search_r...search&x=0&y=0

FastDoc · 03-03-2010, 03:44 PM

That's the kit I bought. Might be a defective valve or some crud. I'll look at it when I get home. Might be able to get by without pulling the carbs.

FastDoc · 03-04-2010, 11:54 AM

I need some advise men.

The leak is fixed, but I have a 'hanging idle'. It's from a vacuum leak at the carb boots where they mate to the head. I ID'ed this by spraying carb cleaner at the area and the hanging high idle (4000 RPM) can right down until the cleaner evaporated.

New boots for this bike are not possible to find, and the replacement boots (used) are what's on there now.

Any type of a sealent I can use that will stand the heat AND the exposure to fuel?

This is my last issue that keeps this bike from being a daily driver!

A crazy(?) idea I've had is to spray the boots with bedliner (redneck but maybe a good idea) to seal them or dip them in that plastic coating used for coating tool handles, but I don't know if that stuff will take the heat. I don't know if bedliner will flex without cracking when I put the carb bodies back into the boots. Ruberized undercoating is yet another thought.

Someone help! :oops:

katoranger · 03-04-2010, 12:07 PM

Not sure if the RTV is available in black. It worked really well for me.

I think the tool dip and bedliner would be okay with the fuel, but I don't know about the heat.

Allen

FastDoc · 03-04-2010, 12:18 PM

Look at what I found:

http://cgi.ebay.com/ebaymotors/Kawas...item23046a0c2d

Maybe there was supposed to be a gasket there that was tossed by some prior owner?

SpudRider · 03-04-2010, 12:36 PM

Quote:

Originally Posted by FastDoc

Look at what I found:

http://cgi.ebay.com/ebaymotors/Kawas...item23046a0c2d

Maybe there was supposed to be a gasket there that was tossed by some prior owner?

It appears a missing carburetor boot gasket might be the problem, Doc.

If this is the case, you shouldn't have much difficulty making that gasket yourself.

Spud

katoranger · 03-04-2010, 12:41 PM

I think my yamaha had the gaskets and a suzuki gs used o-rings to make that seal.

The gasket should be easy to make.

Allen

FastDoc · 03-04-2010, 01:06 PM

Suggestions on what to make it from? Should I use a sealer on it? Its not a big job but enough of a PIA I'd rather just do it once more.

Cal25 · 03-04-2010, 01:11 PM

You can get gasket material at an auto parts store. RTV sealant could also be used but I would prefer the gasket as clean up would be easier if the job had to be done again later.

Reveeen · 03-04-2010, 02:02 PM

Gasket material (auto parts store, though in a pinch cardboard would do (the non-corrugated kind). Lay the material over the surface on the head, and using a gasket hammer, make the gasket in about 20 seconds. High temp RTV would do it too, just allow a good dry time.

03-03-2010, 07:53 AM	#32
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I had RTV sealed boots on my radian. Did the job. Also you can make a video for us. 85 on a little bike like that is fast enough. __________________ You meet the nicest people on a Honda Clone.
	0

03-03-2010, 11:26 AM	#34
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	The KZ400 site was instrumental and helped me with my project very much. 85 is plenty fast, it was just a way to test power output. the bike felt very fine at that speed. I don't have it done. Oh the joys of antique bike repair. this AM there was puddle of gas under left carb drain, the needle valve must be defective, incorrectly installed or some dirt may be in there. Also the vacuum slide diaphrams, while intact, are old, swollen, and balky and will get replaced. __________________ Happy to serve.
	0

03-03-2010, 02:44 PM	#36
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	A friend is sponsored by this Canadian company. He races in the WERA series vintage bikes. http://www.siriusconinc.com/search_r...search&x=0&y=0 __________________ You meet the nicest people on a Honda Clone.
	0

03-03-2010, 03:44 PM	#37
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	That's the kit I bought. Might be a defective valve or some crud. I'll look at it when I get home. Might be able to get by without pulling the carbs. __________________ Happy to serve.
	0

03-04-2010, 11:54 AM	#38
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I need some advise men. The leak is fixed, but I have a 'hanging idle'. It's from a vacuum leak at the carb boots where they mate to the head. I ID'ed this by spraying carb cleaner at the area and the hanging high idle (4000 RPM) can right down until the cleaner evaporated. New boots for this bike are not possible to find, and the replacement boots (used) are what's on there now. Any type of a sealent I can use that will stand the heat AND the exposure to fuel? This is my last issue that keeps this bike from being a daily driver! A crazy(?) idea I've had is to spray the boots with bedliner (redneck but maybe a good idea) to seal them or dip them in that plastic coating used for coating tool handles, but I don't know if that stuff will take the heat. I don't know if bedliner will flex without cracking when I put the carb bodies back into the boots. Ruberized undercoating is yet another thought. Someone help! :oops: __________________ Happy to serve.
	0

03-03-2010, 08:42 AM	#33
Reveeen Join Date: Jun 2009 Location: orbital platform Posts: 741	This may be of some help: http://www.kz400.com/index.html
	0

03-03-2010, 12:43 PM	#35
Reveeen Join Date: Jun 2009 Location: orbital platform Posts: 741	I have had, well, "reasonable luck" replacing the steel needle valves with viton rubber tip valves stolen out of automotive carb rebuild kits. (otherwise give the needle a rap, on the blunt end, with a gasket hammer)
	0

03-04-2010, 12:07 PM	#39
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Not sure if the RTV is available in black. It worked really well for me. I think the tool dip and bedliner would be okay with the fuel, but I don't know about the heat. Allen __________________ You meet the nicest people on a Honda Clone.
	0

03-04-2010, 12:18 PM	#40
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Look at what I found: http://cgi.ebay.com/ebaymotors/Kawas...item23046a0c2d Maybe there was supposed to be a gasket there that was tossed by some prior owner? __________________ Happy to serve.
	0

03-04-2010, 12:41 PM	#42
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	I think my yamaha had the gaskets and a suzuki gs used o-rings to make that seal. The gasket should be easy to make. Allen __________________ You meet the nicest people on a Honda Clone.
	0

03-04-2010, 01:06 PM	#43
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Suggestions on what to make it from? Should I use a sealer on it? Its not a big job but enough of a PIA I'd rather just do it once more. __________________ Happy to serve.
	0

03-04-2010, 01:11 PM	#44
Cal25 Join Date: Feb 2008 Location: Terrell and Grapevine Tx. Posts: 1,585	You can get gasket material at an auto parts store. RTV sealant could also be used but I would prefer the gasket as clean up would be easier if the job had to be done again later.
	0

03-04-2010, 02:02 PM	#45
Reveeen Join Date: Jun 2009 Location: orbital platform Posts: 741	Gasket material (auto parts store, though in a pinch cardboard would do (the non-corrugated kind). Lay the material over the surface on the head, and using a gasket hammer, make the gasket in about 20 seconds. High temp RTV would do it too, just allow a good dry time.
	0