KZR's Bikes of the Month for 2024

KZ400 Exhaust Swap

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19 Sep 2024 04:53 - 19 Sep 2024 05:22 #904450 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
They do, though I'm not sure it'll be the right size but I've a handful of them that are used for the drain plug on oil changes and the ones for my truck might be big enough to fit the header pipes.

*Edit, checked and the ones I've got are far too small unfortunately so i'll just plan on ordering the copper ones as it seems they'll get here the soonest and match the factory part numbers.

'76 KZ400
Last edit: 19 Sep 2024 05:22 by ThatYeti.

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19 Sep 2024 05:20 #904451 by Wookie58
Replied by Wookie58 on topic KZ400 Exhaust Swap

They do, though I'm not sure it'll be the right size but I've a handful of them that are used for the drain plug on oil changes and the ones for my truck might be big enough to fit the header pipes.
I meant in reference to "exhaust gaskets" - generally drain plug (and other sealing washers) are flat washers which don't have enough "collapsibility" to do the job required here. If you can find something please share but motorcycle seals shouldn't be that hard to source (IMHO)
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19 Sep 2024 05:24 #904452 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
I do have some that are for automotive applications and are the same 'crush style' that seems to be called for here but they're much too small for the exhaust header apparently. Doing a search online and the only place I'm finding these are E-bay, happy to take other recommendations if others have a better source.

'76 KZ400

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  • ThatGPzGuy
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19 Sep 2024 05:30 - 19 Sep 2024 05:31 #904453 by ThatGPzGuy
Replied by ThatGPzGuy on topic KZ400 Exhaust Swap
Z1 shows these as out of stock. Partzilla also shows them as unavailable. There are a few on eBay. 
Bundle 5 New OEM NOS EXHAUST GASKET SET 11060-1242 78' 79' KAWASAKI KZ400 | eBay

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"
Last edit: 19 Sep 2024 05:31 by ThatGPzGuy.
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19 Sep 2024 05:44 #904454 by Wookie58
Replied by Wookie58 on topic KZ400 Exhaust Swap
Have you considered measuring the header diameter and going to your local motorcycle store. You could buy to "size" rather than specific part number or application ?

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19 Sep 2024 06:32 #904457 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
This was the plan if I couldn't find anything to get here sooner.

'76 KZ400

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19 Sep 2024 06:33 #904458 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap

Have you considered measuring the header diameter and going to your local motorcycle store. You could buy to "size" rather than specific part number or application ?
Don't have any shops local that work on these old bikes unfortunately, just Harley's etc. unfortunately.

'76 KZ400
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27 Sep 2024 15:17 - 27 Sep 2024 15:34 #904669 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
* Edit* Disregard, stared at it long enough and figured it out. Pipe has to go first apparently.

inally have all the bolts/gaskets/clamps. Took it all apart without issue...but of course as I'm putting it back together, I'm pulling my hair out trying to remember how the header pipe mounts to the engine. Followed the diagram and my memory but it seems like there's nothing keeping the pipe against the block. The 'collar' that sits around the pipe is large enough for the pipe to go in and out without stopping it and my recollection (and the diagram) makes it look like that's what holds it but I have to be missing something.

'76 KZ400
Last edit: 27 Sep 2024 15:34 by ThatYeti.

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27 Sep 2024 15:35 #904671 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
Question that's not in the diagram, are the mounting points for the pipes meant to go directly into the bike frame? I've got brackets/metal strips with holes there from the aftermarket units it came with and the stock pipes are like half an inch short of making it to those studs.

'76 KZ400

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27 Sep 2024 18:42 #904673 by TexasKZ
Replied by TexasKZ on topic KZ400 Exhaust Swap

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
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27 Sep 2024 19:02 #904675 by ThatYeti
Replied by ThatYeti on topic KZ400 Exhaust Swap
Thanks and it looks like there may have been a second pic that didn't load but the one that did is hard to tell how it mounts, is there a bracket? Or does it mount right to the frame stud?

'76 KZ400

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27 Sep 2024 19:29 #904676 by TexasKZ
Replied by TexasKZ on topic KZ400 Exhaust Swap
No extra bracket. The welded on bracket slips over the end of the foot rest mounting bolt.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
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