Please, school me on Jet sizes / sourcing...

[nightmoves]

*// Basically, I'm looking for the proper way to restore a carburetor back to its original factory jetting and where to source the parts necessary to do so. //*


After taking a deeper look at my carbs last weekend, I've come to the conclusion that the previous owner really had no idea what they were doing and just went to swapping out jets with reckless abandon. One jet was missing, almost all of them are stripped, and some don't even match their respective mates in the opposing carb. I would start with replacing the sizes I have already, but they're so far off I need to replace them all at once.

So, I need to get back to a factory default carb setup with the factory jet sizes, that way I have a reliable baseline from which to actually tune the bike properly. Seeing as how I'm still relatively new to bike maintenance, this is my first carburetor overhaul. I checked my factory manual and found this:

1982 Kawasaki KZ440 A LTD Belt
Jet Needle- N02A
Main Jet(primary)- #70
Main Jet(secondary)- #88
Air Jet(pilot)- #125
Air Jet(primary main)- #130
Air Jet(secondary main)- #50
Pilot Jet- #35

I scoured the forums and elsewhere to confirm part numbers and matching jet sizes, but there doesn't seem to be a clear explanation for finding this info. For example, I made my way to PJ Motorsports and found that they offer a "sizing guide" for various models (but don't guarantee their suggested sizing information). They suggest KeiHin N424-26 for the slow / pilot jet and KeiHin 99101-393 for the main jet. So, I guess my question is, which jets are which in relation to the info my manual gives? Am I missing something really fundamental here? And is there a better place to look for individual carb jets? I also checked DynoJets, JetsRus, and Zenterprises, but just got more confused as I went on.

I apologize in advance if this is a dumb question. I'm trying to learn as much as possible on my own, but this one has really got me stumped at the moment.

Thanks!

 

[danker16]

you got the same stock jets as mine.

what jets do you need specifically?

you can find the Slow jets/pilot jets on Siriusmotorsport.com and the Primary mains #70s or bigger and Secondary Mains 88s or big/smaller or Zenterprises for really cheap! look at the carb exploded views from the manual or Kawasaki website and let us know which ones you need. Unless you really want to change them regardless, here they are

I doubt you'll need any needles.
secondary main jets
http://www.z1enterprises.com/ItemDetails.aspx?itemDescription=Keihin+99101-393+Type+Round+Main+Jets+%2388&item=SIKHM-110088

primary main jets
http://www.z1enterprises.com/ItemDetails.aspx?itemDescription=Main+Jets+Keihin+%2370+99101-ZF5&item=SU019-411

slow/pilot jets
http://www.siriusmotosportsinc.com/eshopprod_cat_8661-62504_product_1589309.MIKUNI_PJ_PWM_PWK_SLOW_JET.htm

http://www.siriusmotosportsinc.com/eshopprod_cat_8188-47197_product_1336915.CYCLE_PRO_PILOT_JETS_FOR_KEIHIN_CARBS.htm

 

[nightmoves]

So, this is as far as I've gotten by piecing together all the info I can find. I'm mostly unsure of the Pilot Jet (48) and the Needle Jet (61). I just want to make sure I'm matching up the right jets / needles to the right suggested sizes before I go buying them.

 

[danker16]

what i linked you is what you need. for the needles maybe someone can help you find them on JETSRUS they are about 12.00 a piece. or Keyster makes a full rebuild kit for it here from siriusmotorsports as well.

http://www.ebay.com/itm/KAWASAKI-KZ440-LTD-KEYSTER-CARB-KIT-1980-1983-/291049501231?pt=Motorcycles_Parts_Accessories&hash=item43c3e6f22f&vxp=mtr

 

[nightmoves]

Awesome. Sorry, I'm a little slow sometimes, especially when it comes to making connections between reading about / seeing / ordering parts I actually need. There's so much information out there that sometimes it can be overwhelming to make the right purchase the first (or second or third) time.

Thanks for the help, danker16! Do you happen to have any updates on your KZ build? I'm interested to see what you came up with for a frame and seat modification. Mine was a serious feat to get looking good.

 

[nightmoves]

Off topic, I know, but I'm also having some trouble finding a spot / modification for my indicators after switching out the cruiser bars for superbike bars as well as changing out that boxy tail light. I'd be interested to see how you moved those around. But I'll probably end up searching the forums a little harder or starting a new thread.

Thanks again!

 

[danker16]

it couldn't mount the stock turn indicators on the front anymore without any of the stems from older models, I did a really ghetto fix but was very flimsy and the lights fell off I replaced them with some LEDs on the front. the seat and frame mod is still on the drawing board due to the fact that I dont know how to weld and unless I can get a good job done on the cheap I wont be touching it.

I think your bike looks great and would hold off on it until you got good plan for it.

do you have the stock airbox and exhaust?

 

[VonYinzer]

Don't buy Keyster kits. Never right. Buy what you need piece by piece.

 

[nightmoves]

do you have the stock airbox and exhaust?

I have the stock exhaust and I lucked out and was able to buy a stock airbox here on the forum. It took me a couple of months to track one down, but it was worth the wait.

Thanks for the pointers on the indicators. I think I'll try to find a decent LED headlight with integrated signals next. As soon as I get the carbs back to factory performance I plan on leaving everything as is and just enjoying a well-running bike.

 

[nightmoves]

Don't buy Keyster kits. Never right. Buy what you need piece by piece.

Cool. I sortof found that to be the case with 6Sigma as well. Or maybe it was just my lack of experience in ordering jets. But either way, they didn't help. I guess I've just had some trouble isolating the exact jets I need to purchase. Pretty sure I'm just going to have to make an educated decision, order a set of individual jets, and go from there.

Thanks for the help guys!

 

[danker16]

Cool. I sortof found that to be the case with 6Sigma as well. Or maybe it was just my lack of experience in ordering jets. But either way, they didn't help. I guess I've just had some trouble isolating the exact jets I need to purchase. Pretty sure I'm just going to have to make an educated decision, order a set of individual jets, and go from there.

Thanks for the help guys!

order your jets from z1 enterprise, since they are so cheap i'd order multiple sizes pair of 88s, and a pair of 92s just in case. stock main prim are 70s ( i never understood what the primary main does; people are talk about the mains aka secondary mains and pilot jet on these carbs. not even the manual gives a good explanation on them. ) you can get the pilot jets from Jets R US aswell.