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Discussion Starter · #1 ·
Hi everyone!
My KZ440 has been sitting for about 10 years and now I'm getting it back into shape.
I have encountered lots of problems with the Keihin Carbs.

1- Then I found out one of the diaphragms is teared and that It had been repaired by someone in the past with some kind of brown silicone (What is it?!?) and now some of it got loose and left the tear open again (Its about a 2mm tear you can see against the light but reading about it I realized its an important defect) - So the question is how can i repair this small tear? (At least to get it running untill I order new ones... Here in Portugal there aren't any)

2- During all this assemble/disassemble, fit in/fit out of the carbs I managed to lose a small part of one of the carbs (And hated myself for it!!) and my question is to understand what is it for and is it essencial! ;) - Ok, I lost one of these Polyester Caps that sit inside the bowl, above the PILOT JET #35, part nr 110121128 (I checked all this in an online parts fiche) - Both of them were already very "loose" in the alloy housing above the jet... The o'ring is/was very worn out.. I still have one and by the overall state I wonder what are they doing there... if their doing anything at all...

3- These carbs were already without the PILOT SCREW PLUG that seals the PILOT ADJUSTMENT SCREW and wonder if this also is an important part I should try to acquire...

3 "small" questions... Hope to get a lof of answers!! :p
Thanks
 

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Discussion Starter · #4 ·
1. Read this thread. http://www.kawasakimotorcycle.org/f.../92592-carburetor-diaphragm-repair-works.html

2. Yes you need that part so you will need to replace it.

3. You don't need to replace those caps but it would be a good idea to make sure the o-ring that seals the mixture screw is in good shape and not leaking.
Thanks! Lots of usefull info in the "diaphragm repair that works" page... Problem has been to find the equivalent products here in Portugal - I´ll probably need to go to a specialists shop or something...
And about the #2 question - Do you know where I can buy these polyester caps? The repair kits dont seem to bring any... ANd if I cant buy them do you have any ideas of how I can replace them for something else?
Thanks for all
D
 

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Other than buying some junked parts carbs I'm not sure where you could get a replacement. I thought I was going to have to come up with one for my carbs when one got misplaced for a short time. I was going to make one out of round aluminum stock and just cut a grove for the o-ring. BTW mine are made of aluminum so I guess the material doesn't really matter as long as it's fuel resistant and it's the right size to cause the o-ring to seal tight.
 
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