View Full Version : '76 kz400 chop project

04-05-2015, 2:15 PM
So I've had this sitting in the garage for a year or so after picking it up on CL on the cheap. When I got it it ran fine for the test ride and about 15mi, then died on me going about 70 on the interstate. Initially I assumed gas or carb issues and with a little research stumbled upon the "phantom fuel" problem. After getting her into the truck and home I could get 'er fired up on full choke after a batt charge. Decided to take her for a spin around the block and while turning out of the alley across the train track, got the front wheel caught and laid it over. Couldn't get er started after that (a good time to mention it's kick only) and noticed I bent the shift lever (more on this later...) along with tearing up a few other bits here and there (tag/taillight etc). So then she sat in the garage for a season while I went about my business and sorting out problems with my Ironhead(ache)

About a week ago I decided it's time to give this bitch the overhaul she's been screaming for, so here goes.

First off I tore the bike down from what shape I bought it in.
<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150321_002.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150321_002.jpg" border="0" alt=" photo WP_20150321_002.jpg"/></a>

<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150322_11_36_49_Pro_1.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150322_11_36_49_Pro_1.jpg" border="0" alt=" photo WP_20150322_11_36_49_Pro_1.jpg"/></a>

that was day one. this is the result of day two:
<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150327_23_55_40_Pro.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150327_23_55_40_Pro.jpg" border="0" alt=" photo WP_20150327_23_55_40_Pro.jpg"/></a>

<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150327_23_59_01_Pro.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150327_23_59_01_Pro.jpg" border="0" alt=" photo WP_20150327_23_59_01_Pro.jpg"/></a>

Separating the motor and frame on a jack by myself proved to be simpler than I had imagined, though it was not trouble-free. That's what I get for doing this at 1am.

More soon.

04-05-2015, 2:20 PM
Oh yeah, the rat's nest wiring harness I pulled out like a tumorous knot:
<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150321_004.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150321_004.jpg" border="0" alt=" photo WP_20150321_004.jpg"/></a>

and the killer full kustom brake light:
<a href="http://s547.photobucket.com/user/z_hughes/media/WP_20150328_004.jpg.html" target="_blank"><img src="http://i547.photobucket.com/albums/hh446/z_hughes/WP_20150328_004.jpg" border="0" alt=" photo WP_20150328_004.jpg"/></a>

Yes that is a spray paint lid. I gotta give the PO some credit, that light fits perfectly in that cap. Twas meant to be.