1976 Kawasaki KZ400 Street Tracker Build

1976 Kawasaki KZ400 1And this bike is done. Sure there are a few more little details that should be taken care of, but you have to leave something for the new owner to personalize, right?

Here’s where we started. This 1976 Kawasaki KZ400 had sat behind someones house in Burbank, CA baking in the sun since at least 1989 (the last sticker on the license plate). It had been heavily toured when new, ridden a little for ten years afterwards and put away, at least with a dry gas tank.

1976 Kawasaki KZ400 before 11976 Kawaski KZ400 before 2





1976 Kawasaki KZ400 before 31976 Kawasaki KZ400 before 4







What did it take to get running again? Well first the pistons had to be broken free of the bore. A quick hone and  new stock size rings, and it was time to put it back together. It was actually harder to find gaskets than the find piston rings for it, because this is the early “smiley face” cylinder head with an exhaust crossover in the head.

KZ400 smiley face 1kz400 smiley face 2







The next big challenge, after cleaning out the microscopically small pilot jet holes, was finding new intake boots. I ended up buying a set of KZ1000 police bike boots, and making a set of 1/4″ aluminum spacer/adapters.

KZ400 intake 1kz400 intake 2





KZ400 intake 3KZ400 intake 4







The next project was the exhaust, which is the stock head pipes, with “cheese grater” baffles in them, and generic turn down ends.

1976 Kawasaki KZ400 2You can also see the intake tubes, which are auto parts exhaust pipe, thru widened holes int eh cut down stock air box, and Uni foam filers inside.

The seat is cut down stock foam on the stock pan, with a custom stitched cover on it.

kz400 seat 1kz400 seat 2





kz400 seat 31976 Kawasaki KZ4003





What else needs to be said? It runs and drives great for what it is. I hope to be able to run it on a flat track, but not sure I can make that happen in the next few weeks, and I need to move it out to make room for the Bosozoku project. So I am entertaining offers on this one, running, ride it home, legal and registered, waiting for new title in the mail.

Here’s the big gallery