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Re:My second Kz440 1981 12 May 2015 09:27 #671761

  • dom2570
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My chain snapped the other day...It was only matter of time. Pushing the bike home in the rain at 2am sucked, but that is life.

I have the new chain and sprockets, but am having issue removing the sprocket cover. PO ruined the heads. What is the path of least resistance when it comes to getting this bastard out?
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Re:My second Kz440 1981 12 May 2015 09:45 #671765

  • loudhvx
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Get a sharp, small chisel, and gently tap the screw in the places shown. It must be sharp to not slip off.
Do not hit hard.
You are NOT trying to bust the head off.
And, at first, you are not even trying to turn the head.
You are just trying to move the head a tiny bit one way, then the other. You should see the head move sideways a tiny bit, but not necessarily turn.
Keep doing it evenly one side then the other.
Eventually, after several times, the head should start to turn a tiny bit.
If it looks like the chisel is about to slice a chunk of the head off, then start again at two new positions.

This method takes some experience to get the right touch, but I have been able to get almost every screw like that out using this method for over 30 years.

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Re:My second Kz440 1981 12 May 2015 09:53 #671767

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THANK YOU, worked like a charm!

Time to fine some new hardware!
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Re:My second Kz440 1981 12 May 2015 14:10 #671811

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That is not pretty.

In case you haven't seen it, look for one of Ed's posts on how to make a JIS screwdriver from a Philips. (The jap bikes do not use Philips heads, they use JIS heads.) The taper inside the cross is different and Philips drivers mangle the JIS heads pretty quickly. You can get JIS drivers online, which is the preferred option, but if you check out Ed's posts, that does work.

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Re:My second Kz440 1981 12 May 2015 14:15 #671812

  • SWest
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Get some Allen heads. End of problem.
Steve
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Re:My second Kz440 1981 12 May 2015 14:29 #671815

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what did you set the valves to? I have an 81 kz440 and I put a .007 gap and it seems to be running ruff

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Re:My second Kz440 1981 13 May 2015 14:36 #671966

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If i remember correctly I set them at .19mm because the manual said between .17 and .22mm, .007in pretty much converts to .18mm?

Do you have the stock airbox? I have learned that these bikes are super picky about their intake but really flexible when it come to the exhaust.
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Re:My second Kz440 1981 13 May 2015 14:40 #671967

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Today I got the new muffs, chain and sprockets installed. It was pouring rain but she was a blast to ride! The shinko 712s surprisingly do really well in the rain.

I had a hell of a time getting the counter sprocket off. Yes, at the beginning of the day that hoe was in one piece. :pinch:
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Re:My second Kz440 1981 13 May 2015 14:42 #671968

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I got a little picture happy...I am really digging this bike.
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Re:My second Kz440 1981 13 May 2015 14:57 #671969

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1981 kz440d short pipes!:
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Re:My second Kz440 1981 17 May 2015 12:02 #672501

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I got my "carb rebuild" kits yesterday. I figured out it would have been easier and simpler to just buy the parts I needed individually because I didn't use most of the crap that came with the kit.

I did install new float needles, float bowl gaskets, and plug o-rings, and air fuel needles.

This morning she fired right up and after a bit of adjusting was running great.

I never did figure out where exactly I was seeping fuel from, but I no longer have seeping issues
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My second Kz440 1981 19 May 2015 10:50 #672738

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I broke it yesterday. I Think it is time to get the balls to try and pull the engine and see what damage was done... :(
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