'80 kz440 A1, starting issues, died while riding

Hello everyone!

I recently bought a 1980 kz440 model A1. It was has been running great up until a few days ago.

First...
It starts rough. I have to have the choke all the way up for a few minutes, lower it to new positions until the bike adjusts (with throttle help), and continue until it either:
1) idles at ~1000rpm
2) dies and I repeat what was stated above until it works and idles or it continues to be stubborn and I can't try again for 3++ hours (flooded?)

Second...
My manual says that it should idle at 1,100-1,300rpm, so I adjusted the idle screw after getting it warmed up. After idling for 5 minutes, I went for a ride, but the bike gave out after a few minutes, as if I hit the engine cut-off switch,
Ever since then I haven't been able to get it to run.

I tested the ignition coil, relay, and spark plugs, all check out.
I then used engine starter and it finally turned over, then died out.

Does this point to a carburetor problem? Maybe that's why I have such a hard time starting it as well, the air/fuel mixture is off?

Any direction is greatly appreciated!!
Thanks,

- Chris

Compression, fuel and spark, what don't you have.
Have you performed a compression test?
Have you pulled the plugs and checked for spark?
What do the plugs look like?



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You might check valve clearances if you haven't done that yet.

What does 'dies' mean? Meaning the starter won't even spin, it is completely dead or the starter spins but the bike doesn't even try to cough or start?

Nebr_Rex:
The plugs are totally covered in carbon which I believe is because of the air/fuel mixture being adjusted. Other than that they still produce a spark, but I am replacing them.
I have not tried a compression test yet.

M_a_t_t & Nebr_Rex:
I read online that if you're motorcycle doesn't start, but you use engine starter and it does start, that means something is going on with your carbs. The engine starter bypasses what the carbs usually do (if that's what I read correctly). So if it turns over and runs then your ignition system, compression, and valves are A-Okay. I could look into it though.

ajsfirehawk:
By 'die' I meant the engine is running, but when I put the choke down and keep on the throttle, slowly letting it to the idle area. Then when I released the throttle it would just turn off I suppose is how to describe it, as if it weren't warmed up (after 5 minutes of running with throttle) or like fuel wasn't getting to it.

Thanks!

Have you clean the carbs, it looks like a lean mixture condition.
Pull them and take look inside the bowls and jets for rust and dirt particles

Okay so today I cleaned that carbs. I put the petcock in prime for 15sec to allow fuel into the empty float bowls and it started up right away! Yay!
But....I had the choke all the way up and was using the throttle. As soon as I started to let the choke down and eased off the throttle it would die, just go straight down to '0' rpm's. It started up again, but same issue.

Maybe I didn't let it warm up enough, or maybe there is a fuel problem where it's just not getting enough?

Also it is now making this horrible starting noise I attached....sounds like something is grinding!
Any ideas? I believe it is coming from the very bottom front of the engine, like where the 'Kawasaki' logo is on the picture I attached.

Your attachment does not work, try you tube.
The symptoms you described indicates a plugged pilot jet/idle circuit.


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The choke is an enrichening circuit. A bike dying after disengaging the choke sometimes indicates plugged pilot circuits as they act as the idle circuits. Try cracking open the throttle a little, then close the choke. or set the idle higher.

ps: how many miles are on the motorcycle & have you done a valve clearance check. a non-start problem, especially after warming up the engine, is a symptom of the clearances out of adjustment,

Perhaps orifices 4 and/or 5 into the bore are still clogged.



Good Fortune!

Nebr_Rex:
Well I believe you were right about the pilot jet. I couldn't clean them the first time I went through the carburetors because I didn't have a thin enough flat-head. Bought one, went through a second time cleaning the pilot jets and even going through them with a tiny wire.

Patton:
I think I sprayed those...thanks for the diagram though! I just noticed those two holes and didn't know where they went, but decided to spray them anyway. Now I actually know where they lead.


After cleaning the pilot jets, I was able to start the bike even without the choke.
Now here is where I'm at...
I leave the petcock in 'Prime' for ~15sec (is that enough time?) to allow fuel into the empty float bowls. Switched petcock to 'On'.
I can start the bike perfectly, and it idles for maybe 2minutes, then acts as if it runs out of fuel and shuts off smoothly.

So I did a simple test:

I waited a couple minutes, left the petcock in 'on' and tried to start the bike = Nothing

Then I put the petcock into 'Prime' for 15sec again and tried to start it = Worked great

I believe this is pointing to some fuel issue. I'm going to check the petcock today, maybe something is wrong with the vacuum?

Thank you everyone for all the help so far, I'm learning a lot :]
Note: the weird starter clutch noise is gone.

Pull your petcock and check the screen to see how clean it is or is not.
It will be just 2 bolts.


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