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KZ650. Carb #3 spitting fuel out. Wont start

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27 Aug 2022 14:18 #872958 by TexasKZ
Replied by TexasKZ on topic KZ650. Carb #3 spitting fuel out. Wont start
Yes, that is a problem. There should be nothing between the shim and the follower. That was likely the result of somebody making adjustments without any shims handy. It is a very risky thing to do, and could lead to catastrophic engine failure. Toss all of them in the trash and do it right.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24

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  • Scirocco
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27 Aug 2022 18:58 #872972 by Scirocco
Replied by Scirocco on topic KZ650. Carb #3 spitting fuel out. Wont start
Looks like some one want to be save some money and fill the gap with some feeler gauge metal to get in spec. No way, but you are lucky smart guy to find the no-brainer and save your engine!

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  • BlackEyeCafe
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27 Aug 2022 19:00 #872973 by BlackEyeCafe
Replied by BlackEyeCafe on topic KZ650. Carb #3 spitting fuel out. Wont start
Okay will do. They are super thin, maybe .03mm , so you are probably right about the “adjustments” thing.  I just hope the previous owners didn’t drop any into the valves.
I’ve been fixing “quick fixes” since I bought this bike.  Buddy was running a partially burnt wiring harness under his seat. I re-wired the whole bike

1977 KZ650 C
Jets - Main 115 - Pilot 17.5 - Needles - Position 3 - NGK BR7ES

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28 Aug 2022 04:40 #872992 by hardrockminer
Replied by hardrockminer on topic KZ650. Carb #3 spitting fuel out. Wont start
Are the shims under the bucket?  And did the PO put metal under the bucket too?  Wow!

I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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28 Aug 2022 06:08 #872997 by TexasKZ
Replied by TexasKZ on topic KZ650. Carb #3 spitting fuel out. Wont start
If those pieces of metal are shifting around, or if a couple of them fell out while you rotated the engine, that could explain some of those odd measurements. Be sure to look carefully around and inside the valve springs for any wayward bits.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
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  • BlackEyeCafe
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28 Aug 2022 18:05 #873034 by BlackEyeCafe
Replied by BlackEyeCafe on topic KZ650. Carb #3 spitting fuel out. Wont start
I will try to get some photos on Tuesday.  Can the valves be removed and replaced in order to check below or would that throw everything out of whack?

1977 KZ650 C
Jets - Main 115 - Pilot 17.5 - Needles - Position 3 - NGK BR7ES

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28 Aug 2022 19:05 #873038 by TexasKZ
Replied by TexasKZ on topic KZ650. Carb #3 spitting fuel out. Wont start
The valves cannot be removed without removing the head. I would try looking carefully with a flashlight an a small maybe a small mirror before taking the engine apart.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
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30 Aug 2022 12:15 - 30 Aug 2022 12:23 #873095 by BlackEyeCafe
Replied by BlackEyeCafe on topic KZ650. Carb #3 spitting fuel out. Wont start
So I took everything apart today removed all those makeshift shims which were about. 25 mm. Then I measured, with a calliper, all the existing shims and all the existing shims regardless of their written number (2.65 or 2.75)were about 2.40 to 2.41. I measured a new Hot Cams 2.75 shim and it measured 2.75. 

I’m not sure what to do from here. I only have new shims that are 2.75 and 2.80 from Hot Cams and none of the local shops carry them. A Hot Cams kit is roughly $120 shipped but it’s at least 2 weeks away.   

Any ideas?

1977 KZ650 C
Jets - Main 115 - Pilot 17.5 - Needles - Position 3 - NGK BR7ES

Last edit: 30 Aug 2022 12:23 by BlackEyeCafe.

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30 Aug 2022 12:21 - 30 Aug 2022 12:21 #873096 by Warren3200gt
Replied by Warren3200gt on topic KZ650. Carb #3 spitting fuel out. Wont start
What I would do is to put 2.40 in all the buckets and measure the gap. You can then calculate which sizes you actually need. Once you know that you can buy individual shims to keep costs to a minimum.
There is no short cut or make do until you have the correct shims. 


Z1000J2 somewhat modified!

Last edit: 30 Aug 2022 12:21 by Warren3200gt.
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  • hardrockminer
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30 Aug 2022 12:33 #873100 by hardrockminer
Replied by hardrockminer on topic KZ650. Carb #3 spitting fuel out. Wont start
I agree with Warren.  And I recommend you go to Kawasaki for your new shims.

On thing that I noticed in the photo, and maybe it's just the angle, but do you have two different diameter shims?  

I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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30 Aug 2022 12:35 - 30 Aug 2022 14:15 #873102 by BlackEyeCafe
Replied by BlackEyeCafe on topic KZ650. Carb #3 spitting fuel out. Wont start
Got everything back together and these are the results 

1 - 2.40   .127
2 - 2.40   .178
3 - 2.40   .254  need 2.50
4 - 2.40   .254  need 2.50
5 - 2.40   .178 
6 - 2.40   .178
7 - 2.40   .305  need 2.55
8 - 2.75   Too tight ( lost the 8th original shim somehow) guessing it will be similar to #4

I believe that all the shims are the required 13mm diameter 

1977 KZ650 C
Jets - Main 115 - Pilot 17.5 - Needles - Position 3 - NGK BR7ES

Last edit: 30 Aug 2022 14:15 by BlackEyeCafe.
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  • Scirocco
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30 Aug 2022 15:17 #873111 by Scirocco
Replied by Scirocco on topic KZ650. Carb #3 spitting fuel out. Wont start
I wouldn´t trust the parallelism shape and measurements of any grind down shim.

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