TOPIC:

I have an '82 KZ440 that I am stumped. I have 3 options: 1. Trash the bike, 2. take it in to a service shop to be fixed or 3. fix it myself.

Here is the situation - it starts when cold with the choke open and runs with the choke open. When I close the choke the idle speed drops to 1200 and idles ruff and when I give it some throttle, it stalls. I open the choke and it fires up and the same process, as above.

THen when the engin is hot, it won't start at all - Just cranks with choke open or closed.

I have the coil tested and it is good both hot and cold.

Anyone have ideas or suggestions?

I am getting to the point of loading it into a pickup and taking it to be serviced.

Thanks,
Lou

Check/adjust the valve clearances??

I was afraid someone was going to suggest valve clearance. How hard is that and is it something a hack can do?

Its extremely easy on your model, so much easier than on the bigger KZ'S. kz400.com
You should be able to find instructions to do it here.

Also check that your IGNITION TIMING ADVANCER is working properly. Everytime I pick up a new KZ the only thing really wrong with it is that the ignition timing advancer is frozen shut with rust.

Also, are your carbs clean? Your fuel flow to the carbs good? You got good (new) gas? Do you have good spark (new spark plugs+wires?)

Theres no reason to have to bring your bike into service, usually the rates are ridiculous IF you can find a place to do it at all.

Gummed idle circuits in the carbs? Maybe try running some Sea Foam through it by adding it to the gas and see if that helps.

Valve clearance is good advice as is a compression test.

- Nate >>

We ran Sea Foam thru the carbs and no real change - I took the carbs off today and someone hacked the jets on one of the carbs that I need to fix but overall the carbs looks real clean, which may have been due to the Sea Foam.

Since the carbs are out, I am going to fire up the air compressor and blow out the jets and other passage ways in case there is junk clogging up the holes.

I replaced the spark plugs and the plug wires look good as well. I think my next steps are:
1. Blow out the carbs
2. Compression test
3. Ignition timing advancer
4. Valve clearance

Any other ideas ?

I had problems starting and running my 440 when I first got it too. The problem with mine was that the jets were drilled out (as well as missing parts of the carb) so I was flooding the engine all the time.

Durare

Were the jets missing - What happens when the jets are drilled out - Don't you have to install larger jets?

I was missing a piece of the needle jet and the pilot jet was still useable but the center hole was drilled out to 1/8". I remember the previous owner saying he used a drill and the jets cleaned right up!!! Nice and shiny!!

I bought a used carb and grabbed the jets and the pieces I was missing out of it so I could run the bike. Its been running on those parts for about 2 years now.

I recently bought new jets and the gas flow is restricted to a hole size thats probably smaller than the width of a sewing needle (vs the 1/8" hole the previous owner created!) So come this winter I'm getting the used idle jets out and putting in the new ones.

With the original setup the bike would start but not idle at a low speed. Also, you couldn't get out of 1st gear cause it would stall. It took alot of time to figure that one out.

Good luck with the bike!!

Durare