Changing Plug wires on 76 KZ750 Twin

Hey guys,

Semi new to KZ750s. I am familiar with the xs 650 and some cbs and triumphs, but new to kawis. Got this one about a year ago. Got it running pretty well, but just giving it a tune up to try and make it maintenance free for the rest of the summer.

Here are some photos as i hate threads without pics...







I ordered some new plug wires, but didnt realize that you can not remove the old plug wires from the coil. WTF?

Is there anyway to replace the wires? The ends are melting and deforming and the plug boots will barely screw onto the ends. Ive cut off a couple inches and the ends of the wires are still goopy enough so that the screw on plug boots barely stay...

I already have the wires... can i just solder the new wires on to the old ones farther up where the plug wire is in better condition?

Thanks in the advance...

Welcome westonboege, I like the mods to your 750.

Yes plug wires on these are a biatch.
If you have at least 2" of good wire at the coil a splicer can be used (from Z1 Enterprizes)
NGK Plug Wire Splicer
TU38-1024
Used for splicing new wires on old coils. Joins two sections of plug wire together.
$5.57

A replacement coil with wires is also available and reasonable.
I doubt soldering will work on the plug wires but have not tried it myself

Good luck
Jim

IF you have the OE coil pack like this

then the ribbed caps just unscrew. If not, then yes, you can buy the splices OR just get new coil pack. From what I remember they are not too bad like around $35. For the cost differences of the joints versus new you might be better off just to replace due to the peace of mind knowing the chances of it going bad is less because they are new.

Nice bike BTW.

Thanks man. Z1 has quite a bit of stuff. Was really hoping to see some jets... Ive been searching for main jets forever, as i have switched to pods and reverse megaphones im running lean on the main circuit.

Anyone know of a place to get jets?

Also anyone know if yamaha xs650 carbs will fit on the 750? 750 has BS38s Mikunis and so did alot of the years of xs650s. I just dont know if the carbs are interchangeable?

Thinking about getting a set of flatslide keihins for the kawi, but need to do some measurements to see if they will fit...

any ideas?

i just got jets at the local shop for 2.75 each on z1enterprises just search main jet no s

I think that one, and possibly two, sources for BS38 jets for the 750 twin have been located.

Search Kawasaki twin owners forum for details.

I checked on the twin owners forum and cannot find anything.

I searched main jets on z1 and all they have listed are for the keihin carbs...

I did some research today, and the carb boots will fit on the kz750 if you slot the holes about 1-2mm on each side. The inner diameter of the carb boots is pretty close, but not exact.

I think I am going to get some of the aluminum carb holders for an xs650 and get a set of VM34s or VM36s for the 750 twin. I can machine them on the mill at work to slot the holes slightly so they match up. Then I will have plenty of jets to choose from and no cv carb stuff to worry about.

Z1Enterprises can get any jets you require.

Just phone them.

westonboege wrote: I ordered some new plug wires, but didnt realize that you can not remove the old plug wires from the coil. WTF?

Is there anyway to replace the wires? The ends are melting and deforming and the plug boots will barely screw onto the ends.

Z1 Enterprises sells an EMGO four Ohm coil which will work for the 750 twins (I am running one on mine) with new wires included for $36. There are kits with splicers and wires and they cost that much or more.

Hear me now, believe me later: If that is a 30+ year old coil, it needs to go before it starts giving you all kinds of misery. Guess how I found that out....

steell wrote: I think that one, and possibly two, sources for BS38 jets for the 750 twin have been located.

Search Kawasaki twin owners forum for details.

Correct, but last time I heard, Z1 was not one of them (unless they have recently started stocking the tiny main jets). The pilot jets are BS30-96 and everybody has them. The mains are very rare, but the kawi twins website has two sources listed that do carry them.

westonboege wrote: I checked on the twin owners forum and cannot find anything.

Here you go:

www.armbell.com/kz400/viewtopic.php?t=12916&mforum=kz400

www.armbell.com/kz400/viewtopic.php?t=11589&mforum=kz400

I believe the correct main jet type is 100.606, but check to make sure.

Thanks for the links Bountyhunter!

I will have to look into the jets.... As hard as these seem to be to find parts for and as touchy as they are im leaning towards switching carbs.

Ive already drilled out my mains with some kit I bought off ebay that was complete crap. The bike runs really well, but is still too lean above 3.5-4k rpm in 5th.

And the right side is running way leaner than the left. Sprayed the carbs down and found a leak near the throttle shaft seal. The mixture screw on the right has to be out like 1.5 turns more than the left to even out the mixture... haha.. Definately something funky going on...

I could fix them, but im leaning to the lower maintenance and easy to find parts of the vm roundslides... easy to synch and find jets for...

This is my daily beater so I need the reliability so I can work on my other projects without being down a bike...