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1981 kz440, changed the oil... now it wont start.. 02 Sep 2014 22:15 #646067

  • FaultedGeologist
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KzHeadach wrote: The air filter element isnt stock though... its a piece of a shopvac filter I cut to fit... so ill be getting a new one of those. It needs new intake boots as well. Right now they pass the carb cleaner test but there covered in JB weld and that isnt right. While im at it think ill get some new sparkplug wires. These ones work fine and look fairly new but it apears the previous owner glued them to the nuts on the end and, even though im getting spark, they might not be enough of it... so I guess I have a little bit of a shopping list... does anyone know a good place to order parts? Im tired of rigging everything I can on this bike.


Everyone here suggests Z1 Enterprises (google it) for parts. They shipped mine ultra fast every time. I am fighting my bike as well, but piece by piece it gets better. Get the cables and new plugs if they are sooty. They sell the airbox carb boots, and that makes a huge difference in putting the carbs back on (less headache)!

I found the replacement KN air filter on Amazon that matches my model.

Seone also recommended getting a Gunson Colortune to help set the fuel air mix. Google it and watch the youtube video, it looks like the most fun tune.
Clint a.k.a. Faulted Geologist
1980 KZ750 LTD H4
FSMaunual: kz.bike-night.com/media/GPz750-full.pdf
Stock except for:
New chain and sprocket (530?).
Dynatek Ignition

NO PHILLIPS HEAD SCREWDRIVERS!!
kzrider.com/forum/10-new-members/603905-new-member-kz750-1984-project#742729
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1981 kz440, changed the oil... now it wont start.. 02 Sep 2014 22:38 #646069

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Btw, you want the copper core cables; the suppression cables are for new vehicles that have sensitive electronics, and they can make things not run right on your bike if you have resistor spark plugs.
Clint a.k.a. Faulted Geologist
1980 KZ750 LTD H4
FSMaunual: kz.bike-night.com/media/GPz750-full.pdf
Stock except for:
New chain and sprocket (530?).
Dynatek Ignition

NO PHILLIPS HEAD SCREWDRIVERS!!
kzrider.com/forum/10-new-members/603905-new-member-kz750-1984-project#742729
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1981 kz440, changed the oil... now it wont start.. 02 Sep 2014 22:47 #646072

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I found a downloadable FSM for your 1981 KZ440 here: www.kz400.com/WorkshopManFrameset-5.html

It is a fun read.
Clint a.k.a. Faulted Geologist
1980 KZ750 LTD H4
FSMaunual: kz.bike-night.com/media/GPz750-full.pdf
Stock except for:
New chain and sprocket (530?).
Dynatek Ignition

NO PHILLIPS HEAD SCREWDRIVERS!!
kzrider.com/forum/10-new-members/603905-new-member-kz750-1984-project#742729
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1981 kz440, changed the oil... now it wont start.. 08 Sep 2014 18:54 #646766

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I finally had some time to tinker a little bit and I realized that in order to get enough tension on the clutch cable to shift, the 2 line adjustments have to be taken all of the way out to the last threads... correct me of im wrong but id say thats a pretty good indication that my clutch is worn out... I saw that the PO had put some washers on the cable to shim it out and take up some slack(wrong cable maybe?). So just in case its the wrong cable, is there any other way to tell if the clutch is bad?
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1981 kz440, changed the oil... now it wont start.. 08 Sep 2014 19:48 #646774

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Perhaps there's excess gap in the clutch push-rod adjustment.

If not already done ---




Good Fortune! :)
1973 Z1
KZ900 LTD
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1981 kz440, changed the oil... now it wont start.. 08 Sep 2014 19:48 #646775

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I don't believe that is any indication of a worn out clutch. A worn out clutch will slip regardless of the cable or clutch adjustment. If it was mine I would buy a new, correct cable and adjust the clutch properly (not just the clutch cable) using the instructions in the Kawasaki Service Manual. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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1981 kz440, changed the oil... now it wont start.. 09 Sep 2014 10:17 #646849

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Patton wrote: Perhaps there's excess gap in the clutch push-rod adjustment.

If not already done ---




Good Fortune! :)


I saw this procedure in the manual but it seems this bike doesn't have this. Instead it's blocked off under that cover. I'll send a picture when I get off work.
*scratches head
Is there another adjustment I can make other than the 2 on the cable?

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1981 kz440, changed the oil... now it wont start.. 09 Sep 2014 11:21 #646864

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You need to sort out why the clutch adjustment screw and locknut are missing. They are needed to adjust the clutch. Pictures will be interesting to see. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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1981 kz440, changed the oil... now it wont start.. 09 Sep 2014 16:44 #646912

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I havnt pulled that plug out yet but this plug lines up with the hole that the clutch push rod adjustment should be... I havnt removed anything in this area other than the covers
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1981 kz440, changed the oil... now it wont start.. 09 Sep 2014 16:51 #646913

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Hold on - yours is a 1981 belt drive, so if it is a D3 not a D2 it may have a different clutch arrangement! Look for something like what is shown in the diagram below. Also, take a look at the manual in the link below, especially starting at page 300. Ed

www.kz400.com/Workshop%20manual%20bilder...Service%20Manual.pdf

Attachment 00003_2014-09-09.jpg not found

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1981 kz440, changed the oil... now it wont start.. 13 Sep 2014 20:32 #647445

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Patton wrote: Perhaps the clutch cable adjustment at the perch is too tight and won't allow the clutch to engage. There needs to be a little slack in the cable when the lever isn't being squeezed..

Perhaps the clutch cable is binding or kinked or mis-routed so that it can't function properly.

Perhaps the clutch is failing to engage due to needing a clutch push-rod adjustment which creates a slight gap between the clutch actuator assembly and the end of the push-rod.

In any event, it sounds like the clutch is for whatever reason failing to engage.

Good Fortune! :)


+1000
I realized that after I tinkered with the clutch cables and got the appropriate slack, I never tested it to see if that was the problem. So I did today and it works better than ever! Takes off real well, theres some issues on take off still though. I wont be able to troubleshoot them out u till I start getting new parts ordered and in place. So now my shopping list is as follows:
Carb holder boots x2
Clutch cable
Petcock rebuild kit
Spark plug wires
Air filter element
...
I feeel like im forgetting something... might take a while to get all of this but ill keep you posted as I accumulate them

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1981 kz440, changed the oil... now it wont start.. 24 Sep 2014 20:55 #648706

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KzHeadach wrote: I guess I have to take back what I said earlier about it "running perfectly"
It had very little pick me up in first gear. I had to keep my foot down on take off to keep myself from tipping the bike over while giving it alot of gas. Once I got past 20mph or so then she would take off pretty good. Im guessing this prlly had something to do with the air/fuel mixture...

Still sounds like the pilot needle is clogged. Search for the Patton method of cleaning carbs and have another whack at it. A set of guitar wires had the right size to clean mine out.
Clint a.k.a. Faulted Geologist
1980 KZ750 LTD H4
FSMaunual: kz.bike-night.com/media/GPz750-full.pdf
Stock except for:
New chain and sprocket (530?).
Dynatek Ignition

NO PHILLIPS HEAD SCREWDRIVERS!!
kzrider.com/forum/10-new-members/603905-new-member-kz750-1984-project#742729

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