Removing Throttle Assembly Off Carb!!

Hi folks!!! Newbie here with a question!! VERY limited experience with engines, so please go easy on me!! Rebuilding my Kawasaki kz440 Ltd and have the carbs off, but how the heck do you get the throttle assembly off?! Any help would be much appreciated!!!

Just a thought Lrock, but pictures speak a thousand words or more. If you could post one of the problem area you are referring to it would no doubt help you get some replies. By the way, do you have a factory service manual for your bike? Just so you know, they hold a lot of valuable information.
Rick H.

The parts diagrams at Partzilla might help. also, EB pics are handy for stuff like this.
Taking a stab at it, you might need to separate the carburetors.

Off the Handlebar? You said throttle assembly, two phillips head screws from underneath if that is what you're referring to?

They are JIS screws. If you use a Phillips screw driver on them, you may wreck the screw heads. If you have the factory tool bag, it has the proper tool in it.

The thread title says "Off Carb," so he may mean the throttle shaft and lever. If that is the cas, I would say, leave it alone. To remove the throttle shafts one from each carburetor, the butterfly plates will have to be removed from the shafts. They are often held on by two small staked screws. They are hard to remove and harder to replace. Remove the rest of the parts from the carburetors, clean everything VERY thoroughly, and reassemble with new gaskets and orings. Make sure that the throttle shafts turn easily and smoothly while you have everything else apart.

asphalt900 wrote: Off the Handlebar? You said throttle assembly, two phillips head screws from underneath if that is what you're referring to?

WARNING - as TexasKZ said there are no phillips head screws on your Kawasaki - they are Japanese Industrial Standard (JIS) and using phillips screwdrivers on the will wreck them. If you need info on how to modify phillips screwdriver tips to properly fit those screw just ask. Ed



JIS screwdriver tip