Starting a rusty '80 KZ440D

Ok folks. I'm officially starting the KZ440D restoration thread. I'll get some pics up as soon as possible but this project will likely move a bit slower than the 750e. Since I have a bike to ride, I'm not in a rush anymore. So far I've cleaned out the gas tank with vinegar (I recycled the vinegar from the 750 gas tank cleaning, worked fine) However the petcock on the 440 blew out on me on day 3. All the vinegar leaked out. Luckily by that time it had done its job. Rinsed it out with baking soda and water. Dried it out with some alcohol and then some air. The following day I decided I'd line the tank with some POR-15 (first time). Coating went flawlessly. Was surprised how much POR-15 I poured back into the can (reusable?).

I started to examine the petcock I noticed it had a large crack in it and a big chunk of material was free from the rest of the component. So, that petcock is toast. Any aftermarket petcock suggestions? This bike might largely be updated with aftermarket parts. The turn signals are smashed, the handlebars are bent, the headlight bucket is cracked, the gauges are cracked...and on and on. So, I'll either try to find a parts bike to supplement this one or update this bike with some aftermarket parts since I've never had that experience. Long way to go. The carbs on this bike were pretty well abused with gouges and stripped jets. Thanks to another member on the forum I got a pair of clean carbs and am currently double checking it's function. I'll try to hook it up to the aux tank soon, slap a battery in it and try to get her to start. If she runs, then it's off to the races.

What's the bolt hole spacing for the petcock? a Yamaha Raptor fuel valve might be an option. I think the bolt holes are 34mm center-to-center. They come in various shapes >> some are kind of squat & fit close to the tank, while others hang down more. You can find new ones on EB for around $25 >> pretty cheap for a new oem made in Japan fuel valve. Someone on another forum put one on his Zephyr 550 or 750. I forget.

..

Hey folks. Have a question. What was the stock primary jet size for the 80 kz440 LTD? Was it 68 or 65? I have two sets of carbs, each with a different jet size.

Tvag06 wrote: Hey folks. Have a question. What was the stock primary jet size for the 80 kz440 LTD? Was it 68 or 65? I have two sets of carbs, each with a different jet size.

I think I figured it out. I have a '80 kz440 D. It came with a set of carbs with #65's in it which leads me to believe they are not the originals as the D1 parts diagram lists #62 or #70 as stock. One carb body was damaged with a thrashed jet. So I then purchased carbs that came with #68 jets. I'm presuming it was rejetted for pods and were originally off a D2-D4. So I think I'll purchase another #65 which should be the jets for this set of carbs off a D2-D4 with a standard airbox. How can I ensure I know what carbs I'm looking at?

While I search for another #65 jet, I've taken to stripping the kz440 to the frame. I've hit a snag at the front sprocket. It's clearly a known issue on the forum. Yesterday I tried (in vain) to remove it with a 11/16 socket and my impact driver. I only gave it a couple tries as it was late at night. Yes, I pushed back the washer tabs. The rear wheel started spinning and so I figure I'll give it another go with a piece of wood between the wheel spokes (5 honking big spokes). Before I give that a go, I'll heat it up with a torch for a couple minutes. That's the plan anyhow, I'll let you know how it goes.

While I search for another #65 jet.........,

Z1 Enterprises sell keihin jets for $2.25US each.
Click on their banner above, type "keihin" in the search box and I think you will find what you are looking for on the second page

Jeezum Crow! I missed that, big time. Thank you! I'll buy two of each at that price.

Ok. I printed out both parts diagrams for the '80 kz440 D1 and the '81-83 kz440 D2-5. I cross checked every single part to see if there is any difference between the two carbs. I can tell you with all certainty, the only difference between the D1 and the D2,3,4,5 are the Primary Jet (according to the parts diagrams if they are at all accurate).

Keihin 80 kz440 D1 - had either a [strike]#70[/strike] or a #62
Keihin 81-83 kz440 D1,2,3,4,5 - had either a [strike]#70[/strike] or a #65

SO, the only way to tell what set of carbs you have is to take a look at the Primary Jet. The set I took off my '80 D1 had 65s leading me to believe they came off of a later version of the 440 at some point. The set I bought came with #68s leading me to believe they have been rejetted as none of the stock kz440s came with a #68.

Leading me to my final question. Do I...

1. install #65s
2. install #62s
(I am ignoring #70s figuring those are for racing)

If you are using the factory air filter and box, plus a factory exhaust system, I would probably start with the 65s and see how they work. Surprisingly to some folks, the factory jetting on a stock bike works quite well.

TexasKZ wrote: If you are using the factory air filter and box, plus a factory exhaust system, I would probably start with the 65s and see how they work. Surprisingly to some folks, the factory jetting on a stock bike works quite well.

Would you still recommend that even though my bike is an stock the 80 D1 which shows the stock jet as the #62?

Oh, sorry. I still had in my mind that it is a 440. I would start with the stock jetting, and adjust only if necessary.

TexasKZ wrote: Oh, sorry. I still had in my mind that it is a 440. I would start with the stock jetting, and adjust only if necessary.

HA! your confusing me. It IS the kz440 from 1980 (D1). It has the same carbs as the successive years models (81-83 D2-D5) the only difference being that it had #62s listed as its primary jets and the later models have the #65 listed for primary jets. Did anything significant change between the models or did they just figure the #65s are a better jet for this bike??