Brat-ish build: '81 KZ-440B

I put the carbs in today but the petcock still flows regardless of position and if the bike is running or not. see the thread in the carb section:

www.kzrider.com/forum/3-carburetor/555892-petcock-problemsswap

I got a new petcock in the mail today from Brown Family Racing on ebay. Non-vacuum, so it's much simpler. I put it in and started her right up.

The bike ran and idled great, took it on the road and it doesn't bog down anywhere through the throttle. The carb-holders and cleaning out the valve seats must have done it.

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BUT it still leaks out of the drain nipples. I adjusted the floats and if anything they keep the fuel level too low, so i'm going to check for cracks in the tube.

What else could be causing the leak?

I pulled the carbs again and will inspect tonight.

Ok, there are no cracks in the tube. i filled the bowls with water while off the carb and they don't leak. I also cleaned the crap out of the valve seats, and it has new needle,valves. I'm lost on what could still be causing the overflow.

If float height causes it, it would mean that the fuel level is too high, correct?

Right now i'm letting the floats soak in a container of water to see if they sink.

Are you using a fuel filter?
If not dirt can be getting between the needle and seat.

When i got the bike, i put on a filter.

Alright guys, my stupidity amazes me. After alll that stuff to try to stop the leak, i spent 2 minutes polishing and cleaning the tubes this morning and found something worth noting:






lol, i can't believe i didn't see those. I even filled the bowls with water to check for leaks, but i guess the differences between water and gasoline made it not leak.

So i suppose the best way to fill these is soldering them? Anyone have any technique, i've never really soldered much besides a few electrical connections.

Thanks guys.

I suggest you read through the following thread....

kzrider.com/forum/3-carburetor/553801-en...t=20&start=20#554472

650ed wrote: I suggest you read through the following thread....

kzrider.com/forum/3-carburetor/553801-en...t=20&start=20#554472

that's a pretty good thread. thanks. so loudhvx recommended using acid flux and lead solder and just torching it on, not using a soldering gun. Is this the method anyone else recommends?

jbeebe1 wrote:

650ed wrote: I suggest you read through the following thread....

kzrider.com/forum/3-carburetor/553801-en...t=20&start=20#554472

that's a pretty good thread. thanks. so loudhvx recommended using acid flux and lead solder and just torching it on, not using a soldering gun. Is this the method anyone else recommends?

I fixed mine by using a micro torch, flux, and solid core solder. You first sand the tube (which you did), heat the tube up (but not too much where it will damage where the tube fits into the bowl), and once hot enough apply solder so it gets drawn into the crack. It will actually suck the solder in so you have to be careful that you don't apply too much solder and thereby clogging up the tube passage instead of just the crack. Apply as little heat as you can get away with. Then just re-sand once cooled.

Before soldering:


After soldering:

Ok guys i jsut finished soldering them up. It's sloppy (due to inexperience), but it holds. I filled up the bowls with gas and there are no leaks. I had some trouble getting the tube hot enough with just the 25W pencil iron, so i had to torch the tube with a propane torch, put some solder on the tip of the gun and lay it on.



ready to go back in tomorrow morning:

You can clean it up flush if you want to spend the time. Just use a small metal file and sand paper. Functionally won't matter. But on the other hand, wouldn't want any chucks to break off that and get sucked into the passages.

I threw the carbs back in this morning. No Leaks.

This is the first time it's running smooth with no leaks and with fully functioning carbs.

It still has trouble getting into 2nd gear. I have to push up on the shifter a few times before it finally sinks in instead of just popping into neutral. into 3rd and up it shifts fine though. any ideas?

Shift fork is bent just a little.
You have to split the cases.