New to ZLs, appreciate some advice

antigramp

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Greetings! I've recently acquired a ZL400, replacing an old Beemer, and I have a few questions :hello:

1. One of the most noticeable differences is the tank, 13 litres vs. 24. And the fuel consumption. I expected a lot better that 15 km/l from a 400! My 30-year-old 1000cc Beemer got 20km/l at legal highway speeds. 150km to reserve (if I'm lucky) and under 200km range is pathetic, not what I'm used to and a bloody nuisance here, there are not a lot of servos on the back roads I prefer and I'm having to stop for fuel every hour or so, to make sure I can get to the next. Strangely, the consumption doesn't vary much from 15km/l no matter if I'm creeping around town on the daily commute, keeping it under 4000rpm, or fanging it on the back roads, going as fast as the roads and the suspension will allow.

2. The front end is pretty light, easily upset by ridges and bumps and a bit floaty in the dirt, needs a very smooth road to go over 130 without twitching and trembling. Big bumps upset it a lot. Might be something to do with the rear weight bias. I'm thinking of trying a different rear tyre next change, it currently has a Dunlop 150/80-15 (front is also a Dunlop, a soft K81 GP designed for classic racing). Definitely doesn't need such a fat tyre on the rear! Which just contributes to drag. Maybe a 130/90-15 (if there's any such thing).

3. I'm not impressed with the handlebar, it makes me look like an, err, BMW rider (with broomstick). I'm tall with long arms, and I find the original bar swept back too far, too high, and (like almost every Jap bike I've ridden) way wider than necessary (see above). I'm thinking about replacing them with what used to be called 'Euro' bars, narrow, low, and almost straight. Looks like it will be no problem, as long as I can find a pair of compatible third-party clamps. That should put more of my weight over the front, too.

4. The air cleaner is turning into a bit of a problem. This model was never sold officially here, mine is a grey import (from Japan). The local dealer doesn't have a listing for this bike (or the 600 on which it is based), the Kawasaki country office is no help either. It's done nearly 20,000km and is probably still on the original cleaner (may account for the fuel consumption). I don't mind importing a replacement, but that would be once, not every year or so. I'll have to look into some third party cleaners, K&N pods or a Unifilter.

5. When I close the throttle, the clutch cable goes slack! I've adjusted it several times, and it's better, but still rather peculiar. Not used to wet multi-plate clutches, what's the go there?

6. The mufflers are partly bodgied, the end caps are missing altogether. I've never had a bike before where the exhaust is more noisy than the wind! The little four-pot screamer must make a serious howl when it tears past at 120 (only 8000rpm, redlines at 12500). Help, help, save me from going deaf! That might be a factor in the fuel consumption too (it does seem a bit rich, the outlets are pretty sooty). Local dealers can't help me with third-party replacements. The Kawasaki dealer said the originals are $550 (each!), yeah, sure.

All comments & suggestions welcome!
Gary
 
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Welcome Gary!
Thats a rare one you got there! Is it a A or B model? Those share parts with the zl600's so you will be looking at alot of those. Check the salvage yards and eBay for used exhaust etc. What kind of mufflers does it have on it now?

I would stick with the factory airbox for the best economy. Also if the exhaust is modified then there's a chance the carbs are too! That may explain the poor economy. Best bet for economy is to verify stock jetting and get the stock exhaust back on. I would bet a good running ZL400 would get very, very good mileage!

Clutch issue is weird? Make sure it doesn't slip by putting it in a higher gear and opening the throttle. If it does it may need a once over.
 
The Zl being a longer bike with longer forks may not handle like you are used too. That being said you need to check your sag and set it at roughly 25-33% of total travel. This is a starting point and we can make adjustments from that.
 
Thanks to all! It's an A model... can anyone point me to some doco that explains the diffs (in case I have to decide whether a B part will do)?

It has the original fat-can mufflers, but it looks like the end plates (with the small outlets) have been hacked off (and whatever packing was inside has long since vanished). I wouldn't have thought that was permitted in Japan, but the previous owner (who bought it from the importer, hence, it is likely that I am the third owner) was a bit of a bush mechanic, he could have hacked up the mufflers, and even jiggered the jets.

I'm keeping an eye out for replacement standard mufflers, and as a fallback, there's a muffler shop in the state capital that can rebuild mine. Probably not cheap, and I'd be without them for weeks. But I might be able to check the jets in the meantime...

Happy to stay with the original airbox, if only I can find a reusable or replaceable filter! Nothing obvious in the Unifilter or K&N catalogues... what does everyone else do for air cleaners?

Clutch does not slip, works well in all conditions. Cable going slack is weird!
 
Mate, I'm confident that a small-engine cruiser has shorter wheelbase than a heavier and faster touring bike (turning circle is probably similar though). I dunno how much it sags, but it had new fork seals (and oil of course) when I first got it. The handling is OK, just a bit flighty, although being a cruiser, it has less ground clearance than even the air-cooled BMWs I've had over the years; I'm often dragging the pegs (without really trying).
 
Welcome and nice find. One thing that I've learned and you might want to think on, is owning a rare vehicle means you'll be hard pressed to find parts. Unless a parts bike can be located life with that bike could prove difficult. Maybe you can flip it at a profit and get a bigger ZL which you will likely like better and be easier to get parts for. Just my 2 cents, if you are good at fabbing parts, the small stuff, you might do OK.
 
That is a good point! I did think of that while considering the purchase, but decided that since it had done only 14,000km, and was cheap, I would chance it. I am not much at fabbing, but I can scrounge, bodgy and plead to skilled artisans with the best of them :help:

I might yet pass it on, for the reason you mention, and after 30+ years on Beemers, it is a bit of a stretch to get used to a high-strung 4-cylinder cruiser. Not that keen on larger bikes at all... this one appealed as pretty much the smallest shaftie on the road. Although the 600 of course is the same size, just more power.

As for the air cleaner, I finally took it out, looking for a part number... but I'm none the wiser, it appears to be bodgied already! A U-shaped metal frame, with two large sides (of two different kinds of mesh), and a block of foam between them. No identifying marks at all. At least it seems in good nick, definitely not choked with dust, and well sealed. I guess I am gonna have to import an OEM part so I know what I'm looking for :laughing7:
 
If the 400 is the same as the 600 series - then the A series is the original model from 1986 ish onwards and the B series is from thye mid / late 1990's.
I am sure somone will give more accurate dates soon!
 
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