KZ400 - Identification needed

[Airious]

I am in of assistance making sure I have all of the parts I need to complete this project ( atleast so it runs ) Let me break down what I know:

Exhaust:

I know I will need two headers, but I am not sure how they connect up to the engine. From what I can gather is a "ring" slides over the exhaust pipes, and then the ring bolts to the engine block, holding the headers snuggly in place. Am I correct in this? Also, do the headers come as the entire pipe, or can I just get the "curved" portion of them, and attach a 1 1/2 inch or so cherry bomb for the muffler?

Carburetors

I am assuming the 305 Carb I have won't fit the 400, so does anyone have any sources I could get carbs pretty inexpensive?

Wiring \ Electrical

Yup. This is were I start to really get confused. Can someone please identify each of the wires coming out of the engine, and what each one goes to? Also if I am missing any that I should have... I have tried to find pictures on google, but none are high enough resolution to follow, and I have never been good at reading wiring diagrams, especially when my application is different

Electric Start

This seems super straight forward, just want to confirm. It is pretty much take off the side cover on the engine, bolt the starter into place, and connect the wire harness? Does the wire harness come with a starter if bought? Otherwise does the KZ400 already have the wiring needed for the electric start, or would i need to buy a separate harness?

This thing on the side

Its in the pic, what in the world is it?

Anything else you guys can think of, I want to end this wall of text, so I will post more later

 

[Airious]

Attached

 

[Airious]

Attached

 

[Airious]

Last two Last picture is the one that has the thing on the side I have no idea what it is...

*EDIT* Actually I am not sure what the first picture is of either. My gut is it is some sort of ignition control, but IDK...

 

[OzFab]

Pic 2 is a pulse fuel pump commonly used when converting gravity fuel systems to a pressure system. Although, I don't quite understand why it's there considering you have a high mounted tank

 

[Airious]

That makes sense, thanks! I have been cruising through the forums all day today and I read another post about someone converting to a 2 to 1 exhaust and there was a mention about something usually mounted to the side, i though that may be it.

I will bypass it when I get everything connected and see if its needed or not lol.

Any ideas on the engine wires? I am pretty sure that the spark uses a jumper wire, would this be normal?

 

[digschopper]

There are 2 half shells like a cars main bearing that go around th pipe,then the ring slips over the pipe from the other end and 2 bolts secure it. I had a 75 with a 2 into 1 header. And k&n's

 

[digschopper]

The electrical box shouldbbe a regulator,he wires coming out of the left engine cover(alternator) should be same colors. I see cut wires. Ignition is right side,2 wires coming out of the small round cover? They. Go to the coils. This engine should have points,not electronic. Later '440's had electronic ignition and a needed 6th gear.

 

[digschopper]

And finally,carbs. Probably mikuni 26mm. The 305 carb may be a 26,but I'm pretty sure it used one carb. The 400 had 2 with a shared choke shaft.

 

[digschopper]

thebscrew-in plug behind the right cylinder is probably the neutral indicator switch. I may have the book for this thing. I'll look.

 

[J_Walker]

Okay, I like working on motorcycles, so this is my thing!

Sadly.. unless you can find a donor engine... you might need new carbs.. I did a little research on bikebandit for you. They say on the website these will fit the kz400.. I'd call them to make sure 100% before buying..

http://www.bikebandit.com/1978-kawa...400c-carburetors-universal/n1139?m=150632&f=3

Also I checked my Local CL, only got one hit on a Kz400 here It's like 3:08 AM and I should go to sleep. I'll look more tomorrow when my brain is fully functioning. I'm sure I'll find something then..

 

[Scout]

thebscrew-in plug behind the right cylinder is probably the neutral indicator switch. I may have the book for this thing. I'll look.

I'd put money on an oil pressure switch.

When you put your exhaust on there should be a copper gasket that goes in the head before the header goes on. A lot of times they get stuck. Sometimes if it's still in there you can re-use them, but I'd recommend new ones. For a bike that old you'd probably have to order some. They are cheap though.

The starter goes in the hole behind the block, you will most likely have to pull the side cover of and put the sprocket and chain on the starter. I'm not sure about the 400/440 but the big brother 750 twin has starter clutch issues, AS long as you have that cover off make sure it is working right. (Should only spin in one direction)

 

[jbrixen]

i have this exact motor laying around, 1978 IIRC. let me look and see what all i have.