83 440D Carb Jet Question / Air Pods

I recently purchased an 83 440 LTD Belt (see pictures). It was running a little rough so I pulled the carbs out, bought an ultrasonic cleaner, and cleaned everything real good. After I put them back in, it still isn't idling right and anytime I have the choke off and yank on the throttle, it dies so I might have an air leak that I need to check out. I bought some new boots for it so I'm going to install those also. I figured while I have the carbs out again, I'll set the air/fuel mixture screw which I didn't check the last time I had the carbs broken down before cleaning. I do not have the stock airbox. I have a set of those cheap mesh air pods so I was reading that people are recommending setting the idle screw to 1 3/4 turns out. Figured I'd give that a shot. I also would like to put a rebuild kit on it and was thinking about installing bigger jets because of the lack of the airbox. I just need to know what size jets I will need and whats a good rebuild kit to start off with. Does anyone also know the stock jet size on this model? I could not find it in the repair manual they have online. Any help or recommendations for this, let me know. Also, I did check the diaphragms out and they seem ok. I didn't see any holes in them. I'll attach some pictures. Good day, gentleman.

Also - Does anyone recommend I replace my air pods with a different set of pods? I have read that they make foam ones that are quite better for this 440. Let me know.

Find a manual somewhere. If this bike is new to you and you don't have a lot of experience rejetting, then you should start with the airbox and getting it to run correctly that way. If it doesn't run correctly with the airbox and stock jets, it's not going to run correctly with pods. It will save a lot of trial and error which can last months.

loudhvx wrote: Find a manual somewhere. If this bike is new to you and you don't have a lot of experience rejetting, then you should start with the airbox and getting it to run correctly that way. If it doesn't run correctly with the airbox and stock jets, it's not going to run correctly with pods. It will save a lot of trial and error which can last months.

That is just it, I do not have the stock airbox. I bought the motorcycle as is and it did not have one, so I'm stuck with the pods. I don't mind re jetting, it's simple to pull off the carbs and pull out the jets so not a big deal. I just need to know where to start with jet sizes and kits. And I have the online manual saved in .pdf format so I'm all good there.

Sorry, I missed that part.

I would do a quick search for an airbox to see if one might be easily gotten.

If not, then the first step is to find a reliable source on what jets were originally in there. A manual might have it, or a parts fiche on a website might have it. If all that fails, then you will have to hope someone posted it somewhere.

Before you start with the jetting, though, the process starts with a compression test, and valve adjustment. Then confirming the ignition timing. Then fixing vacuum leaks. Then confirming fuel flow and setting fuel levels. Then the jetting fun can start.

The Service Manual on KZR should cover your 83 model.

kzrider.com/modules/ServiceManuals/kz440.pdf

loudhvx wrote:
Before you start with the jetting, though, the process starts with a compression test, and valve adjustment. Then confirming the ignition timing. Then fixing vacuum leaks. Then confirming fuel flow and setting fuel levels. Then the jetting fun can start.

Start with what Lou suggested.
Then You will need either K&N or UNI air filters.
6Sigma has a jet kit for the KZ440.
What I use is the DynoJet jet kit for the KZ750/4.
Only half the kit is used but it is a more complete kit.


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Do you know what size K&N filter or UNI filter I will need?

I did see the RC-1060 K&N filter that looks like it will fit. Not sure about which UNI filter fits for a cost comparison.

Thank you to all for the great feedback. Nice to know I have a great source in kzrider.com. I'm going to look into that 6sigma jet kit also.

Try 54mm.


Or 2 1/8"

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