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Removing the carburetor from a kz400 19 Apr 2014 11:43 #629604

  • MannDude
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This is my first bike, and it's a project one at that. I really don't know what I am doing, but am attempting to follow the manual. I'm trying to get to the starter, which means I've got to remove several things before hand.

Now I'm at the carburetor. Manual says, "take off the right and left side covers." Okay done.

Next it says, "Pull off the oil pressure switch lead". Okay, unsure what that is but am Googling to try to figure it out.

"Loosen both carburetor holder clamps and slip them out of place." Okay, the image in the manual points to these and I have identified them... however am unsure how to 'loosen' them. I don't see any screws, nuts or bolts for this particular item anywhere. Don't seem to be able to move them with my hands.

"Spring bands" Unsure what they are but I assume when I get to them I'll probably recognize them.


You see where I am going with this. By chance does anyone have a easier to follow guide for properly removing the carburetor? I can't seem to locate one.

Any help will be greatly appreciated.

EDIT: Photos for reference:







Yes, whoever had it before me spray painted everything silver...

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Removing the carburetor from a kz400 19 Apr 2014 11:56 #629606

  • gd4now
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Not sure what manual you are using, but if you have not do so as of yet you might want to take a look here for help.
www.kz400.com/index.html
www.kz400.com/WorkshopManFrameset-5.html
1977 KZ650 B1
Pods and Denco header


This is my Z

OLD KAW OWNERS SMILE ALOT

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Removing the carburetor from a kz400 19 Apr 2014 12:37 #629607

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I added images to the original post just for reference. I'm using the official service manual here: www.kz400.com/Workshop%20manual%20bilder...Service%20Manual.pdf

Right now everything is removed from the carburetor and it's only in place by what I assume is the "spring band"(?)... I can wobble it a bit and the places it connect to seem rubberized / pliable. Trying to figure out how to remove those now.

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Removing the carburetor from a kz400 19 Apr 2014 13:11 #629617

  • MannDude
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Nevermind. I got it off. Yanked her on out. What a mess. :)


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Removing the carburetor from a kz400 19 Apr 2014 14:08 #629623

  • 650ed
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The previous owner tried to correct carb holder vacuum leaks using that red bubble gum. Your bike desperately needs new carb holders, otherwise anything else you do to it will not make it run properly. Unfortunately, Kawasaki discontinued carb holders for the KZ400 long ago. I don't know if any aftermarket units are available, but you may want to check in over at www.kz400.com and ask what folks there do when their carb holders are shot. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Removing the carburetor from a kz400 19 Apr 2014 14:33 #629626

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From the photos it appears to me that there are no carb holder clamps & no airbox duct clamps either.
In addition to replacing the carb holders, you might need to replace airbox ducts as well.

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Removing the carburetor from a kz400 19 Apr 2014 15:12 #629631

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Thanks for the advice everyone, greatly appreciated.

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Removing the carburetor from a kz400 19 Apr 2014 18:14 #629653

  • ThatGPzGuy
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Here is the new KZ400 forum: KZ400
I think there is a sticky for replacement KZ400 carb holders.
Here is where I go for parts for my 400 www.partzilla.com/ They are good about telling you what is available before you put it in your cart.

The PO of your bike should be horsewhipped...
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"
The following user(s) said Thank You: MannDude

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Removing the carburetor from a kz400 19 Apr 2014 20:49 #629662

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ThatGPzGuy wrote: Here is the new KZ400 forum: KZ400
I think there is a sticky for replacement KZ400 carb holders.
Here is where I go for parts for my 400 www.partzilla.com/ They are good about telling you what is available before you put it in your cart.

The PO of your bike should be horsewhipped...


Thanks for the links, I'll check them out. And yes, I agree about the previous owner. Left her out, exposed to the elements and when she began to rust, he just spray painted over it. There is that red sealant stuff everywhere, too. But, the bike only cost me $200 including the title. I'd say it was appropriately priced for the amount of work that it will need.

My main concern right now is just getting it started. I'll worry about making it look halfway decent after that.

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Removing the carburetor from a kz400 20 Apr 2014 04:13 #629683

  • Nebr_Rex
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The machine is a 440. Carb boots are available last I looked. Get new boots and clamps.
No need for any silicone ( that red 'stuff' ) on a motorcycle engine. Use three bond and
only a thin film of it. The boots do not require the use of sealent. Except when they get old
to seal them at the cylinder head. As far as the air box boots are concerned. I haven't had to
replaced a 440s yet, but have on other KZs. The spring clamps are not real needed if the
boots are still fairly pliable. I think the 750/4s might use the same part. I'll check later today.


.
2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


.

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Removing the carburetor from a kz400 20 Apr 2014 05:35 #629686

  • 650ed
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I suggest you find out exactly which year and model motorcycle you own. That information is absolutely necessary if you plan to own and maintain it because there are important differences between the numerous models, and if you don't know which model you have you will not be successful. So, find out exactly which year/model bike you own and buy the Kawasaki Service Manual for that specific year/model. You will be WAY ahead of the game if you do.

Assuming that Nebr_Rex is correct, and I have no reason to doubt that he is, and your bike is actually a KZ440 rather than a KZ400, he is also correct in that Kawasaki still lists the carb holders for the bike (see image below). Ed

Attachment 00006_2014-04-20.jpg not found

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Attachments:

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Removing the carburetor from a kz400 20 Apr 2014 06:08 #629690

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Dang that has more silicone than aunt Dolly!!! :whistle:
Take it from me cuz I found
If you leave it then somebody else is bound,
To find that treasure, that moment of pleasure,
When yours, it could have been.
1977 KZ650 B1 Being restored to original (Green)
1977 KZ650 B1 Original (Red) Sold
1977 KZ650 B1 Donor Bike for Parts

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