KZ440 Float Bowls not filling after rebuild

Hello KZ Riders! I have been working on my wife's KZ440 LTD 83' and had it running a few weeks ago however, I noticed there was fuel leaking from the left exhaust from a small drain hole. I guessed that there was an issue with the floats or the float needle. I used this as an opportunity to get a couple rebuild kits and start from stock. After replacing all of the jets, o-rings, and needles I put the carbs back on the bike. Now the bike won't start. I noticed that the float bowls don't have any fuel in them. I am very new to all of this so I am hoping you all can help. Usually I am missing something really obvious and you all have been quick to help. Thanks for your time!

I'm having a hard time fathoming how gas is leaking from a drain hole in the exhaust. Unless it's leaking from the carbs or boots down into the pipes.

I am not sure to be honest. I replaced the head gasket before starting the bike up, before the carb rebuild. I thought there may have been oil leaking into the exhaust but what was dripping from the drain hole seemed to be raw fuel and maybe some carbon sooty stuff. I figured there was fuel moving through the cylinder without being burned. From what I recall there wasn't any leaking above the exhaust. Is there anything else that could be keeping the float bowls from filling after putting the carbs back on? Could there be an issue with the fuel air mixture screw?

Well at that point most of this is very simple. Do you have fuel in the tank, is the gas petcock operating type stuff. After it hits the first bowls then it starts to get tricky. Start from square one and make simple tests to confirm that fuel us getting to the carbs.

Nothing is leaking anywhere at the moment tho,right?

Like anywhere?

Doesn't make sense, the head gasket is below the ports. Know what I'm saying?

Doesn't make sense, the head gasket is below the ports. Know what I'm saying? The fuel would wind up in the crankcase.

There is fuel in the tank. The petcock seems to be working when switched from "On" to "Pri" fuel flows . The main fuel line has fuel after disconnecting from the tank. The pilot or primary fuel line seems to be dry. Do I need to leave the petcock in a certain position to refill the bowls after reinstalling them? I cannot find any leaks. But its getting pretty dark outside where I am working at the moment. Thanks for your help, Togoster.

Why did you replace the head gasket anyway?

Yeah call it a day. A lot of times it helps to just retreat, sleep on it. We can tend to drive ourselves a bit hard sometimes.

When the bike was last running, 3 odd years ago the wife said a bunch of oil shot out of the exhaust pipe. I wasn't around when that happened but she suggested the head gasket may need to be replaced. So, we got the bike out of storage and I replaced the head gasket, cleaned the carbs, and had it idling but then noticed the fuel leaking from the exhaust pipe. Pulled and rebuilt the carbs and now we are here... I will give her a look in the cold light of day tomorrow.

Rest assured, there will be some real pros around shortly that will help deduce what's going on.

I reckon there are several problems.
1. Aftermarket carb kits. They are too often of very poor quality. Rarely do any metal parts need replacing, with the exception of the needle and seat valves. Even they do not always need replacing.

2. A leaking petcock and a leaking needle valve can allow fuel to flow when the engine is off. Under the right circumstances, it can seep through a cylinder and down the exhaust pipe. If this happened, the engine oil is almost certainly contaminated..

3. The aforementioned petcock leak. A fuel leak of that nature requires both the petcock and the needle valve to leak.
3b. A bad diaphragm in a vacuum operated fuel valve (petcock) can allow fuel to seep down the vacuum line into the carb and could prevent fuel flow when the engine is running.

4. A paper element fuel filter can also stop the flow of fuel.

I guess I will have to do until one of the experts arrive. :whistle: