1981 KZ400 J2

I don't know if the valve clearances are different from what the 550's use, but make sure to read the warning about the chain tensioner and valve cover. The valve cover should never be bolted on without the cam chain tensioner released.

Here is some valve-timing info you'll want when putting the cams back on.

home.comcast.net/~loudgpz/GPZweb/CamsKZZ...KZZXZR550500400.html

A 4 cylinder 400? Sounds like a good candidate for a Bobber.

Yep.

Going to get it to run right first.

I´m thinking I am going to make it two up. The gf does not like the KTM SM which is one up

Airbox is pretty easy to install if you have new,soft rubber boots where it attaches to the carbs. Most likely yours were rock hard, as are most of the older ones you will find. They aren't that expensive to replace.

Bought a factory service manual from UK, guess it will take some time to get it here.

I have downloaded a kz550 manual, but I am not sure if all the information is the same for the 400.

Am I supposed to measure the valve clearances at TDC or at the back of the lobe. One manual I found says backside of lobe, and the other says at TDC. The clearance actually varies a quite a bit....

Also, still researching what the clearances supposed to be, I am working on the assumtion of 0.05 - 0.15mm on intake and 0.15-0.25mm on exhaust. If that is correct my intakes are way to tight (not able to get a 0.05mm feeler gauge in two of them, but I can spin the bucket, so there is very little clearance. Exhaust is at 0.16-0.22mm

The lobe should be pointed away from the bucket. That's not quite straight up and down. However, the angle is not critical because the base circle should be a constant radius for approx. 180 degrees of cam rotation. As long as the cam lobe is pointing approximately away from the bucket the measurement should be ok.

The measurement does in fact vary slightly around the base circle, so if you take several measurements at slightly different cam positions, you will probably get a few different readings. You should roughly use the average or the smaller of the readings. There's a little fudge factor involved in measureing the clearance. Also, sometimes the feeler will go in with a little more effort, so you have to take that into account as well.

Seems like the spring in the locking mechanism in the cam chain tensioner is damaged. Anyone know the original length and spring pressure is?

I measured the valve cover gasket to be 0.8mm and the oil pan gasket to be 0.6mm. Is there any problem using 0.8mm on both?

Also, anyone know of gasket templates online for these gaskets? Would save me some hassle with the cutting

Should be ok to use .8mm for both. Only the valve cover gasket affects the intake cam timing. I don't think the oil pan gasket should matter.

You can probably get both gaskets somewhere online, maybe even ebay, as long as they ship to your country.

I don't know of any online template.

the manual i have is a haynes, kawasaki 400, 500 & 550 fours.

1979 to 1991 399cc 497cc 553cc

cant find sod all really with teh Z400j and not too much info on parts for teh 55o. lol.

so would i be better getting the manual stated above in this thread?

sorry for the jack

cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem...VIP:watchlink:top:en

found this not a bad price in good condition.. a little help would be great as i soo need new parts and a good manual.