new guy who needs technical help. kz440 1981

hello, I am new here obviously.
i am fairly new to bikes as well.
i own 3 bikes but only one of them runs... well enough to ride that is.
i have an 81 kz440
2001 yzf600r
75 cb500four

i am here to get some technical help with the kz440.

im having a heck-of-a-time getting this thing to run.
the bike was modified bobber style before i got it. which means
that i am not exactly familiar with what the bike is supposed to have in its
stock form. which means that the previous dude (who wasnt very mechanically inclined)
could've taken some very important things off.
case in point, the air filter was gone when i got it and there was this little
ghetto homemade---thing--- in place of an airfilter.
the tank is aftermarket and for some reason the petcock is homeless depot style.
i was reading somewhere about there being a vacuum on the petcock?! idk.

the work that i have done... ie, present state of the bike.
-i tried to clean the carbs. bought a rebuild kit and installed it. (i believe the floats are bad cause they are still leaking, or adjusted wrong.)
-i dont know the exact settings for any adjutsment screws on the carbs.
-still no airfilter.
-i took the head off cause the bike was popping and crackling and sometimes it sounded like a valve was sticking and would crack (loud noise) free and then the bike would die.
i took it into the machine shop where they did a 3 angle valve job and they put it back together with the new valve seals that i gave them.
important note: i didnt give them valve guides to put in. so those could still be bad.
-i got hte head back on the bike and i got the bike to start yesterday.
however it blows white smoke and still pops and cracks. and occasionally makes a loud valve tap.
-i adjusted valves as best as i could since they are hard to get to.
-i ran the bike with the valve access screws off and it seemed to run better. this made me think... why is the bike running better with the valve cover breathing..
so i took off the breather tube and the bike still ran a little better.

-today i started the bike and it didnt smoke at idle, but as soon as i gave it gas it would smoke and pop. it wont hold its own idle. you have to feather the gas to keep it alive, and even then it usually dies.

can anybody help with these problems.

sorry this is so long but i felt that a good history was important.



here are some pics. i added the sissy bar and the tail section (for a license plate and tail light)

wow, u look young. dont forget to put a helmet and boots on when u ride.

welcome.

when u say the floats are bad because there still leaking, do u mean that fuel still leaks out of the carb went it sits, not running ?? if so, then it is the float needle and its seat that are not sealing. Take them back out and press, and twist the needle into the seat. This may help them seat together by removing any accumulated debris. Then set the float level correctly by first doing it with a ruler , then by doing the clear tube test.
Make sure the cam timing is correct, since u had the head off.

yes i mean with the bike off the bowls still leak.
good tip with the clear tube. thanks a lot.
the needles are new but i have not tried pushing them in and twisting. that must be a veteran trick. thanks again.

super glad to have found this site. it took forever to find it, but i feel like im at home now. haha.

that pic is Patton-ted. Don’t wory. U’ll understand why I say that, soon enough. :laugh:

I would just call that tip, a last ditch effort. Lol :whistle:
don’t be totally bummed if they still leak. this is the reason they changed to vacuum operated petcock valves. with a vac operated valve, they automatically close when u turn off the bike. so if they still leak u may just have to shut the petcock off manually.

try to add your bikes model and year in your signature. this will make it easier for the guys to know what bike u are talking about in all future posts. click on my profile at the top of the page. may as well put in , where u are from as well.

Just a thought. if u rename your thread u may get more help from the gurus.
something involving needing help.

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thanks martin.
the vacuum on the #2 carb has been capped. as of yesterday. it was open though.
since the bike was smoking so bad i noticed smoke coming out of there as well.
i want to get the stock air filter back on there. just a matter of time and searching.

as for the frame, that part isnt load bearing. however, i have been able to pick the entire bike up from that part. there will be no weight on it though. especially not human weight.

thanks for all the input.

seems like i really need to get those carbs right before i continue.

this first video is just a run through of some of the things you will need to know before hand.

and heres the second video.
the bike actually starts. seems like its a lean condition. that would be the first bump to get over, but then whenever it does run and sort of idle, and if you give it gas and get the rpm's up, it will ping (like metal on metal, valve tap?) and then die.

anyone!?!?!?

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