1981 KZ 440 Mikuni Carb Install Help

[c_loughridge]

Hello. First time poster looking desperately for some help. I purchased my first bike, a 1981 KZ440 LTD. I'm in the process of doing a single carb conversion with the 11th Hour Industries manifold and a Mikuni VM 34 Carb. I've seen this setup installed on the same type/model of bike but can't seem to figure out why mine doesn't seem to mount correctly. As you can see below in the pics I am having clearance issues with the top of the carb being too close to the backbone of the bike. It's all I can do to get the carb to connect to the hose without too much angle. I'm hopeful that someone with this similar setup can provide some clarity. Thanks in advance.

 

[cxman]

is the manifold upside down?

 

[c_loughridge]

Well the flanges are rotated a bit so it only mounts one way. I'm wondering if the flanges or pipes were welded incorrectly as if they are causing the collector portion to angle up a bit instead of down. I've contacted 11th Hour, not sure if I will get a reply.

 

[Tim]

Looks like the hose between the carb and manifold just needs to be longer.

A quick check of their website and I see this note:

http://11thhourindustries.com/store/#!/Bolt-On-KZ400-KZ440-2-1-Manifold-78+/p/20924335/category=0

*NOTE* The center exit style of this manifold may require some trimming to the backbone of your frame due to interference with the top cap on some carburetors.

 

[c_loughridge]

Thanks Tim, I guess I missed that note. Looks like I may be doing some trimming..

 

[Tim]

Not ideal to be sure - I'd try a longer hose first. It looks like if the carb was just an inch or so further from the manifold it would sit OK.

You can also get curved cable mounts for the top of the carb if cable routing is an issue.

 

[c_loughridge]

That would be ideal for sure. The only concern I have with a longer hose is the carb looks like it would then interfere with the tank mounting bracket just behind the backbone as seen in the 4th pic.

 

[Tune-A-Fish]

Sawsall. Mods are called mods for a reason... adapt and overcome.

 

[c_loughridge]

Sawzall and cut-off saw cured the carb clearance issue. The throttle cable enters the top of the carb so I may have to get creative with routing it.

 

[Tune-A-Fish]

Get a 90 deg or 45 even from Motion pro, they have all that in stock very reasonable. best to just call then email a pic, bet you have it by Saturday!

 

[Tune-A-Fish]

Also. I would clean that up and find a washer that fits the tube size and weld or get it welded in, if you use a cold leather wrap you can minimize paint damage and respray. Just cover everything good if welding with mig the hole in the washer will allow the frame to breath and all will be sweet.

 

[c_loughridge]

Thanks Fish. This is the cable I had already purchased.....should work?

 

[Kamn]

That'll work just fine

 

[Tune-A-Fish]

Thanks Fish. This is the cable I had already purchased.....should work?

Tities and beer mang! No lube on the throttle tube, push it on all the way and back it off just a scoshe