KZ440 LTD Carburettor Tear-down

Jesus, how do you BEND the butterfly valves??  I have never seen that before in 22 years of bike rebuilding...methinks that's some knobjob's idea of "improving performance"...let me guess: it has pods on it instead of the regular airbox...am I right??

lol!!

It is an odd one right enough. 

No, proper air box in place and I’ve ordered a new filter. It’s probably never been replaced. 

 

Does anyone know the internal diameter of the vacuum hose?

I ordered a 5mm fuel hose and it looks too narrow. Should I return it you think?
 

Kawasaki and Partzilla say 5 x 9 x 160.

If you cannot get 5mm locally, 3/16 should do.

I bet vacuum hose would be a lot cheaper.

Thanks TexasKZ. I ordered the right size. 

I’ve dismantled most of the LHS carb. 

I can’t remove the bleed pipe (46) and the needle jet (61). 

Any advice please?

 


thanks

To remove the bleed pipe, use a wood dowel, or similar, entering the carb from the top, where the slide was, put the dowel over the nub of bleed pipe sticking up, then drive the bleed pipe down using a hammer on your dowel.  The orifices through these bleed pipes are tiny, like a pilot jet, so hold them up to a light after cleaning to make sure you can see light come through.

The Needle Jet doesn't need to be removed.  If you want to do so, though, use a similar method.  Just be careful to select a dowel that fits inside the raised cup-shaped lips on the jet, otherwise you may damage the part during removal.  

Oh, something else to do...

Use a cut-off Q-tip, in a drill motor, dipped in brass polish, and clean the float valve seat.  Don't forget to remove any excess brass polish when you finish, since the process will force some in the fuel flow passage.

The float needles have a rubber tip, so inspect them closely.  If the tip is deformed, you need new float needles.  Also, make sure the tiny needle spring is free.  Preemptively changing the needles for new is a reasonable option.  Just watch the quality, if you buy aftermarket.  Keyster makes good needles, and of course Keihin.  Some of the cheap china brands...not so much.

Removed the choke valve plate, flattened it, looks good now. 

Good tip about the polish, thanks. 

Float valves were replaced a few months ago. Hopefully still good, but I will check them. 

Thank you. I used the end of a pencil, with a strip of masking tape on the contact end to avoid lead or wood splinters getting into the needle. 

Re: the dowel pipe - Chopsticks -like, Chinese food bamboo chopsticks - cheap, and work well too. Tapered on one end and gradually expand, perfect for those little venturis. FWIW, I've had great success with Damineding.com carb parts. Just my two cents...