'82 KZ440 LTD Air Box Mystery

Killman77 said:
Shiny ;D

Very first thing I did was swap out the mini-apes for a set of black Euro bars. Makes a world of difference, but it might also mean you want to replace your cables with shorter ones, or keep an eye on your routing. Does mean you have to think about your blinkers though, huh? I bought new 3 wire blinkers and mounted them to the headlight bucket first. Then drilled holes into the headlight ears and mounted them there. Then I picked up a NOS Shoei 1/4 fairing and didn't want to cut it, so I bought some 33 mm clamps and moved the blinkers to the fork legs.
I feel bad, I should've warned you that the bolts, "screws" on these bikes are NOT Philips head. They are Japanese Industrial Standard, "JIS". Get yourself a set of JIS screwdrivers, or you're going to spend the rest of your natural life stripping heads and trying to remove the bastards. Pretty much right off the bat I stripped out the screws on my left blinker and right hand tank badge mounts. Then some nice man clued me in. It's become something of a hobby to replace my fasteners with nice shiny Allen Head Stainess Steel ones as opportunity arises, just make sure to use anti-seize anytime you're mating alloy, (i.e. aluminum) and steel to prevent galling, (seizing like a motherf%&cker).
I also should have told you that to get the carbs out easier, you want to unbolt the airbox and move it back a bit. To move the airbox back a bit, you want to unbolt the battery box and move that back a bit. And if memory serves, to move the battery box back a bit, you'll find it easier to unbolt/unhook the electrics from it, and also remove the rear fender, and unbolt the inner fender and move THAT back a bit. Fun with tools! 8)
That part that you're missing, (3 parts if you count the cage and the foam filter, which is a wet filter) is the snorkel breather I was talking about earlier. Tough to find. Lots of guys switched to pods and chucked the breathers before they realized that CV's are a bitch with pods.

At least you got to take it for a quick boot, that must've felt awesome! Good Job!

Hahaha oh man. I feel stupid. Definitely gonna have to pick up some JIS screwdrivers! Also, should've known that was called a snorkel breather. Oh well, no I know what to call what I'm looking for ;D

And yeah, the 10 minutes I got to ride this weekend was. AWE. SOME. So worth the hours I spent moving parts "back a bit". haha
 
Nothing to feel dumb about, I don't remember you claiming to be psychic. Tough to know something right away unless somebody tells you. While you're looking for the JIS's, you'll want to get yourself a manual, (read whackable with a hammer) impact driver. I've also found that a nice heavy rubber mallet and some different lengths of metal and/or pvc tubing come in bloody handy for a poor man's breaker bar when removing especially tough nuts and bolts. Saves a lot of bloody knuckles.

It's not "technically" called a snorkel breather, I've just seen it called that ;) Gets called all kinds of things, airbox, airbox breather, airbox element, depending on who's looking at it and listing it. The part number will help you out more than anything. I know that there's a member who recently had one for sale due to his moving. You might want to check the For Sale section on the forum.
Dudes have used all kinds of work arounds, balled up t-shirts, what have you, I just like to get the proper part once and for all and have done with it.
 
Guys, I found this conversation incredibly helpful. Thank you! I have all the air box parts, filter, snorkel, etc as well as signal lights that are up for grabs if you are interested. I'm going to pods personally and swapping out to LED for visibility. @nightmoves How goes the bike now? I've done the same as you in starting with a kz440 as my first bike and learning off forums like this one and kzrider. I hope you've gotten a few rides on beast. Did the 1/4 throttle before bolting it back on the bars solve your issue?

Cheers
 
You may also find this helpful. It is an air box/ filter replacement that from what I understand, does not require rejecting your carb.

http://www.kawasakimotorcycle.org/forum/vintage-motorcyle-info/187922-fabricated-replacement-air-intake-kz440.html
 
Berkman said:
Still having top end troubles?

Hey Berkman and everyone,

Time has gotten away from me with a new job, getting married, and moving several states away. But, things are beginning to settle down, so I can get back to work in the garage a day or two a week. Especially now that the weather is nice.

I may just start a new thread here, considering I've stored the OEM air box and carb set on the shelf and have tried going with a single carb conversion from 11th Hour Industries and a UNI filter. It's been ages since this thread had any relevant updates, but here's the current situation:

Carb- Single Mikuni VM34, new
Pilot- 30, new
Main- 155, new
Pipes- Stock
Air Filter- UNI 2-stage, new

Last time I was in the garage, the bike was starting up but was clearly not healthy enough to be on the road. She dies after a half turn of the throttle and recently I've been getting smoke from looks like in and around the pipes. Rather than write up a lengthy report, especially with my limited knowledge, I figured it would be best to shoot a short video and then quickly turn her off and put together a new gameplan moving forward now that I have the time again.

You can check out the clip here.


Like I said, this is the first day I've been able to revisit this long-going project, so I may start a new thread after I address the basics like draining fuel lines, checking compression, changing oil / filter, etc... If anyone has any thoughts right off the bat, give me a shout. Thanks
 
LazloH said:
You still working on this, nightmoves?

Haha, I'm afraid so. 2014 / 2015 has been a crazy year and left little to absolutely no time / funds for the KZ. Luckily, I'm moving up to the Midwest next week and made contact with a couple guys who ride KZ1000's and KZ550's, so I'll be able to bribe them for their knowledge with cases of beer. 8)
 
Haha, no worries. I'm just glad to be back in the garage getting my hands dirty again.

This Tuesday the wife and I will be moving up to Des Moines, Iowa and a long time friend of mine lives up there. He knows a couple guys that go to all the Mama Tried and other cafe shows every year, so it'll be the first time I'll be able to hang out with fellow "vintage" bikers in a long time.
 
hey there! is this post still active? my bike is running like crap due to a lack of an "air cleaner cap". the part you were looking for above. anybody know where to find one? ive searched everywhere on the internet, havent found a thing! thanks!
 
Back
Top Bottom