1981/82 KZ440 Valve adjusting caps

Be really careful tapping on those nuts. They are a thin shell of a casting.
I have rounded off a few with an adjustable wrench. In a pinch a hammer
and chisel to break it loose as not to damage the hex head. Then when reinstalling
apply grease to the mating surfaces and just snug the nut. To much torque
with dry surfaces is the cause of the problem.


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I would soak them with Kroil for a few days and then try to remove them. Ed

Just a heads up on tightening them up. I just had one split on my bike. I found that the reason was after years of tightening it, the threaded part had split a bit from the outer ring. I just snug mine up a bit.
I just checked mine and it is a 27mm.

Unless it's a very thin socket or the engine is removed from the bike, you will need to use a wrench to remove them. A socket will not fit on the exhaust caps between the rocker box and the frame.

Grcko wrote: Just a heads up on tightening them up. I just had one split on my bike. I found that the reason was after years of tightening it, the threaded part had split a bit from the outer ring. I just snug mine up a bit.
I just checked mine and it is a 27mm.

There we go that’s the ticket! 27mm works great. So I took one off (currently fighting to get a sheared carb holder stud out....) and looks like someone did threadseal them who knows when.... lots of flaky black crap on the threads... I’m sure some fell inside when I pulled the cap... now what.

I don't know if it needs to be cleaned out but personally I would pull the cylinder cover off and clean the crap out.

Unrelated to the original topic of this post, but does anyone know, definitively, what the hell the hose sizes are for the vacuum and fuel lines for a 1981 KZ440 A ??

Every post I find and every search I do turns up nebulous results and incomplete answers.

Cheers

Try using this.


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Thanks but I think I’m having trouble getting it to print to the correct scale.

No eBay APP ID and/or Cert ID defined in Kunena configurationDo you not have a ruler, tape measure, carpenter's square, or other measuring device in your house? Does a neighbor have one you can borrow? You can buy them at any hardware or lumber store.
I am sure this one is accurate enough for this project.


If you are dead set against buying a tool, then buy two or three sizes of hose. Use the one that fits, and take the rest back.

Okay so here's another great question that I'm sure will go unanswered - had a starter clutch go one one bike and fortunately had a low mileage parts bike to pull one from. I was able to borrow a tool to get the respective alternator pulleys off, but now I wonder does anyone have any helpful tips on properly torquing the pulley bolt (LH, 51 ftlbs) without the "special" pulley holder tool? Have not for the life of me found anything good, and none of the homebrew solutions I've tried have worked so far.

Cheers to all.

Im pretty sure you can put the bike in gear and have someone stand on the rear brake. That should keep the crank from turning.