My second Kz440 1981

This came in the mail today, I didn't really think it would change how the bike was running too much, but I was pleasantly surprised.

I took her on a 70 mile ride yesterday. For the most part she ran good, but I did have some weird powerband and idle issues. She looked great though!

When I got home, I looked into the timing cover and noticed it was pretty rusty. So I removed it and cleaned as best as I could.

Kz440 Mac 2-2 Open Megaphones:

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Yesterday, I finally mustered up the courage to work on the forks. I replaced the oil, seals, and dust covers. Talk about a pain in the ass, but totally worth it.

I removed the mac exhaust. Cut the stock pipes, and added clubman bars.

Today, I ordered some mufflers, so the neighbors won't kill me, and a carb rebuild kit. This bike is slowly becoming my favorite!

My chain snapped the other day...It was only matter of time. Pushing the bike home in the rain at 2am sucked, but that is life.

I have the new chain and sprockets, but am having issue removing the sprocket cover. PO ruined the heads. What is the path of least resistance when it comes to getting this bastard out?

Get a sharp, small chisel, and gently tap the screw in the places shown. It must be sharp to not slip off.
Do not hit hard.
You are NOT trying to bust the head off.
And, at first, you are not even trying to turn the head.
You are just trying to move the head a tiny bit one way, then the other. You should see the head move sideways a tiny bit, but not necessarily turn.
Keep doing it evenly one side then the other.
Eventually, after several times, the head should start to turn a tiny bit.
If it looks like the chisel is about to slice a chunk of the head off, then start again at two new positions.

This method takes some experience to get the right touch, but I have been able to get almost every screw like that out using this method for over 30 years.

THANK YOU, worked like a charm!

Time to fine some new hardware!

That is not pretty.

In case you haven't seen it, look for one of Ed's posts on how to make a JIS screwdriver from a Philips. (The jap bikes do not use Philips heads, they use JIS heads.) The taper inside the cross is different and Philips drivers mangle the JIS heads pretty quickly. You can get JIS drivers online, which is the preferred option, but if you check out Ed's posts, that does work.