New KZ440 Owner, with questions of course...

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26 Mar 2012 16:14 #512130 by Brett0424
Hello all. I picked up a pieced together 440, built mostly from 80 parts with an 81 engine. I rode it home (probably not the best idea) and now I'm trying to get her tuned up. The first thing I did was replace and re-route the throttle cable since it revved up every time I turned the handle bars. The second thing I've done is ordered new carb holders because the ones on there are cracking. She starts up and runs, but idles really high/erratically. It will sort of rev up on its own and if I even try to push the choke down she redlines. It has pod filters (I know) but that's what's on there so I'm going to try and make them work. The carb has supposedly been rejetted two sizes up, the guy told me 1 for altitude (denver) and 1 for the pods. Here's what I started on today:

Change oil
Change plugs
Adjusted points
Adjusted valves
It looks like I have an automatic cam chain tensioner so I didn't mess with that.

I have worked on a lot of cars but never a motorcycle. Where do I go from here? I've been reading and it looks like I should check float level and sync the carbs. Are these things I can even do with a potential vacuum leak in the carb holder? Is there a good how-to on what things to look at on carbs and in what order? Also, the breather on the top of the motor is just open with nothing on it, i'm assuming I should attach a small hose and a filter to it? Sorry for the long post, I'll get some pictures of this beast up once I get her back together.

80/81 KZ440 frankenstein

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  • mwriders
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26 Mar 2012 16:28 #512134 by mwriders
Replied by mwriders on topic New KZ440 Owner, with questions of course...
Here's a PDF of the shop manual.

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

This is from the KZ400 Web site, which is of course mostly about 400's. But there is a lot of useful material for the 440 there.

www.kz400.com/KZ440MaintainanceFrameset.html

1980 Kawasaki KZ440B (brand new eBaby)
1998 Ducati 900S (gone)
1978 BMW R100S (gone, damn it)
1975 Yamaha RD350 cafe (gone)
1986 Yamaha XJ650 Seca (gone)
1981 Kawasaki KZ440LTD (gone)
1969 HD Sportster (gone :)
1966 Honda CB160 (gone, damn it)
1965 Suzuki 80

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26 Mar 2012 20:25 - 20 Feb 2013 12:18 #512164 by martin_csr
Replied by martin_csr on topic -
never mind
Last edit: 20 Feb 2013 12:18 by martin_csr.

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01 Apr 2012 21:03 #513455 by Brett0424
Replied by Brett0424 on topic New KZ440 Owner, with questions of course...
So here are some pictures of this beast (I didn't do the paint job and it's done with hobby paint).
To add to the above list I
-changed out carb holders and air pods/boots
-cleaned carbs, got new float bowls (overflow pipes were cracked), adjusted the float level, synched carbs and dialed in idle speed/mixture

I guess I'm not sure what everyone's trouble is with pods. She runs fine (I mentioned the PO rejetted), idles fine and has no throttle issues.




80/81 KZ440 frankenstein

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