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Rotbart
06-08-2013, 12:03 PM
First I want to find about this: When on the freeway and in 6th gear the bike will accelerate as long as I stay under 5500 rpm. As soon as I go above 5500 rpm, the engine will rev up but there is no acceleration.

Second: While driving home today I was doing around 65 mph holding around 5500 rpm when she started losing power. I pulled the clutch in and headed for the shoulder and she stalled. I turned the key off and dismounted and looked her over. I couldn't see anything, not that I expected to. She started right back up, but the shifter was kind of strange. I didn't click up or down right away. Finally it clicked down to first and I exited the freeway and took surface roads the rest of the way home. No other issues after that except it seems hard to find neutral now. More than once I thought I had it in neutral, but when I let go of the clutch, she would stall because she was still in gear.

Thoughts or advice?

junkyardjon
06-08-2013, 03:04 PM
When i get home I'll give a reply

horrorbusiness
06-08-2013, 07:05 PM
When i get home I'll give a reply

His 440 is going to need its own sub forum for tackling problems.

Gas Man
06-08-2013, 08:27 PM
Wow. I'm not sure where to start. I think the carbs need a rework.

Pigpen
06-08-2013, 08:54 PM
I would think that at 5500 rpm in 6 th gear you should be going a lot faster than 65. Clutch slippage?

junkyardjon
06-08-2013, 09:32 PM
get carbs sorted out, tune up, adjust everything. running out of steam above 5500.. could be a intake leak.. once you have the basics cleaned and adjusted, then start on any other problems. your clutch may be out of adjustment or bad cable or your springs could be weak or your steel & fibers could be bad. just like every bike you don't know the history on, you have to go throw it. you never know what the owners before have done or really fucked up !!! I've seen some pretty sweet repairs in my time LOL.

Gas Man
06-09-2013, 07:49 AM
How far apart are you from Jon? Perhaps you could hire his services.

Caveman
06-09-2013, 07:52 AM
How far apart are you from Jon? Perhaps you could hire his services.

This

junkyardjon
06-09-2013, 08:58 AM
buy or find a free repair manual on line, this will help you more than anything. the knock or tick could be a valve out of adjustment, cam chain out of adjustment or just a normal noise... hard to tell over the internet. after the bike warmed up, did it go away or quiet down?

Rotbart
06-09-2013, 02:15 PM
I cleaned the carbs, spark plugs look ok. I cleaned the air filters and I'm waiting for them to dry, then I'll oil them, reinstall and take for a spin. I'll let you know.

leebo
06-09-2013, 02:21 PM
I have a haynes manual for kawasaki 450 454 and 500.Dont knowhow close it would be to your bike but its yours if you want it.........

Rotbart
06-09-2013, 03:01 PM
I have a haynes manual for kawasaki 450 454 and 500.Dont knowhow close it would be to your bike but its yours if you want it......... Thanks, I've got one for up to 1981, the bike's an 82, so close enough for government work.

Rotbart
06-09-2013, 03:05 PM
I don't know what I screwed up. She started fine. I let her warm up a little the took her out. After about 1/4 mile she wouldn't drop below 4000 rpm. I don't know if it's the idle screw our the throttle cable. After she cools down I'll try adjusting the idle screw.

junkyardjon
06-09-2013, 07:33 PM
You wanna set idle when the bike is hot, not cold or cooled down. If you set idle when it's cold. It'll idle real high when warmed up.

junkyardjon
06-09-2013, 09:24 PM
Thanks, I've got one for up to 1981, the bike's an 82, so close enough for government work.
from kz400.com?

Rotbart
06-10-2013, 07:44 AM
from kz400.com? No, came with the bike.

Rotbart
06-10-2013, 07:46 AM
You wanna set idle when the bike is hot, not cold or cooled down. If you set idle when it's cold. It'll idle real high when warmed up.I tried when I first got back and burned my hand, that's when I decided to wait for it to cool down.

junkyardjon
07-13-2013, 10:18 PM
carbs are done, sounds pretty good. run of the mill cleaning with new orings and bench sync. the clutch cable adjuster on the cable it's self is soaking over night. after i get the clutch adjusted, it's road test time mahahahaha

junkyardjon
07-14-2013, 09:58 AM
got up to 75mph pretty quick for a small bike. just went for short road test, still needs some minor adjustments but it's running pretty good. back out I go...

Rotbart
07-15-2013, 07:17 AM
Thanks Jon. Nathan said it's 100% better. We even took the freeway home ( his longest run on a freeway).

Gas Man
07-15-2013, 11:13 AM
That's so cool guys!