KZ440 Resto

That looks to be the screw that is used to adjust the sync on your carbs.

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KZ250LTD wrote:

Yupp, def the synch screw. You might want to just pull the carbs and synch the butterfly valves just to know it's done. Might help with the odd running, the nut on that synchronization screw should be locked into position, if not then the synch is more than likely off. If you have a Factory Service Manual it's a breeze to fix, might take half an hour once you know what you're doing.

Yeah I read the PDF manual I have and it recommends vacuum gauges...I am currently without such a device so I am going to sync them with feeler gauges and while they are off the bike I am going to lube the linkages some more and seal some cracks that MAY be leaking...I am giving myself two days for that first test ride.

Well after some good research I decided to make a manometer and decided to go ahead and check the sync of the carbs today. Not good. I couldn't get the bike to stay running more than about 15 seconds but in that time I saw that the left carb is pulling WAY more vacuum than the right carb is. From the level line I put on the ruler the left side is pulling about 6 inches up the tube. This is most likely the source of my idle and engine running problems...spitting and sputtering with some backfiring.

I don't know which side the sync screw adjust, I am assuming the left carb as when I push on the sync screw rather the piece just below it the bikes idle normalizes some what. As soon as I decided to adjust the sync screw the bike cut off, my starter is bad and keeps draining my battery so it is on the charger now. This has to be the problem with the bike...I am almost certain of it now. Can any of you relate to my symptoms and maybe give me some direction or am I on the right track? Also I went to do the point gaps only to find I have no points under the cover...rather some black box with a small piece of metal barely sticking out the bottom of it and there is a small cam on the crank that comes like .3mm from hitting it, at least the feeler gauge was .3mm and was making contact between the cam and the boxes little metal strip.

When the cam lobe is pointing at the little metal strip on the bottom of the black box the timing mark is at "F". This black box has wires that look to go up to the coil. So any suggestions would be great...thanks all, Mike

Well, pretty much tore apart my starter, cleaned it, then charged my battery for 4 hours. Got up today and decided to sync my carbs yet again...this time the bike stayed running...long story short...make sure your airbox is seated correctly and sync those carbs...take a look:

Way to go! Glad you finally got her running. My kz440 gave me similar problems when I first got it.

Well I have another update since my last post...my starter took a dump so a friend of mine ordered a starter rebuild kit from Ebay. It was here for me today when I woke up. So off I went on what I was sure would be a 3 hour tour...a 3 hour tour. Total time was about 40 minutes what with removing covers and the starter. The starter itself took about 15 minutes to rebuild including the testing of the armature and cleaning it. I had a little trouble at first getting the brushes to stay in their housings with all the spring pressure but I got by that with 4 single edge razor blades to hold the springs away from the brushes as I put the starter together. Once the armature was in place and all the brushes were good I removed the razor blades to let the springs apply pressure as they should.

I was skeptical and unsure the bike would start...I need to learn to have faith in myself as the bike fired right up and did it very fast. All I replaced were the brushes, the plate they are on and the O rings for the housing and where it goes through the case and a few washers for the power connection. So now it is all back together and starts every time and I was finally able to put the starter cover back on the bike. My friend also ordered me a set of fork seals and they should be here directly. Once these are replaced and the forks are put back together the bike is road ready as I have already put the new rear shocks on. All that is left after that is cosmetic and a few issues I have with my turn signals.

Always good to hear of another one being brought back from the dead. You'll be busting bugs before you know it.

I did my fork seals and put in new oil and now my ride is not all squishy and scary. I also got a new Helmet as today is my Birthday. It's a Shoei X-SPII Troy Lee Designs and it is cool.

Latest update, the 440 is doing very well and is now ready for it's tags and registration. Also I have a cool jacket to go with my helmet.