Re: '81 KZ440 Installing Airbox
This bike came w/ 2 halfs of airbox. Seems le boucher (past owner), cut it half to remove. Purchased one from auction.
I found no info on the installation of airbox.
So here goes.
1) Remove seat.
2) Remove side covers
2) Disconnect neg bat. Disconnect pos. bat.
3) Remove Bat w/ box and let rest on upright footpeg.
4) Remove regulator assmbly w/ bracket. Let hang on side of bike.
5) Loosen chain adjusters.
6) Remove rear axle nut.
7) Drive rear axle out.
8 ) Remove rear wheel, let chain hang loose.
9) Remove inner fender cover.
10) Bend the forward inner fender cover bracket down. There are 2 to a side welded to the frame, in which the fwd part of fender slides between.
(I could not manage to slide the airbox in w/out doing this.)
11) Slide airbox in w/ the fwd(intake to carb holes ) pointing up. Then once past a certain point, flip box toward carbs.
12) Push the rubber box boots on so that the sealing groove is place. You will have to use a screwdriver to work it in
There is a small cutout where the boot is flush w/ the box. Align this w/ the tiny pin that protrudes from the box.
If not, the airbox boot will be misaligned w/ the carb.
13) Start pushing, banging the airbox toward the carbs. Start the 2 upper box L brackets w/ bolts and slowing draw the box in.
My boots didnt quite line up and were half going on. I had to use a cotter pin puller and go around to start the boot lips on.
14) Tighten box L brackets in.
After 3 months, the bike ran better and will idle w/ no hesitation. Took awhile to warm up though, its 40F.
Found a vacuum plug on the carb(there 1 for each to plug a vacuum port for syncro) w/ minor hole and replaced.
I was also getting some vac leak at the throttle shaft. Sprayed carb cleaner to ck. After the second spray on shaft, it miraculously smoothed idle and stayed that way. weird.
My idle mixtures screws are out 3 turns.
Having owned as many as 25 diff bikes in my life, these 81 KZ440 carbs are not engineered very well. This might be due to the haphazard onslaught of pollution controls back then . Also, I think it would be a poor running candidate for a cafe style bike w/out a complete carb retro.
