KZR's Bikes of the Month for 2024

How to mount clip-ons? ('76 KZ400)

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21 Apr 2024 07:00 #897937 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
I've only had it a couple of months and have maybe 200 miles on it but other than the throttle having a little 'space' before it'll give you gas, which makes parking lot maneuvers a little harder than they should be, it's run as well as I'd expect. Got it as a running/rougher bike which is fine cause it's my first and I wanted someone like that to learn on anyway.

But what's does FSM mean?

'76 KZ400

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  • gd4now
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  • Denco where did you go?
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21 Apr 2024 09:52 #897942 by gd4now
Replied by gd4now on topic How to mount clip-ons? ('76 KZ400)
FSM = Factory Service Manual   

1977 KZ650 B1
Pods and Denco header


OLD KAW OWNERS SMILE ALOT

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21 Apr 2024 10:30 #897944 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Thanks and ya I downloaded the one posted earlier in the thread but didn't see anything that detailed but will check again.

'76 KZ400

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21 Apr 2024 10:35 #897945 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Doesn't show the part where the ends of the throttle cables clip in unfortunately, and obviously won't address having one missing for some reason but any idea which of the two I should be using with the single cable I've got?

'76 KZ400

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21 Apr 2024 13:08 #897953 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Ok, measured 6.25" from the end of the bar, added some tape and pushed the pin into it once it was in place to make a mark, got it punched, drilled a pilot hole and then a matching 3/16" hole like the stock bars had. All mounted up and had the throttle going crazy after kicking the start a million times. Turns out it was just giving it all the gas. Took it back apart, moved the throttle end piece to the second slot and it's working as it did, will say it doesn't pull back to 'off' throttle as quickly but hopefully that'll fix itself.

Really happy with how the bars look, though I think they're off center by a tiny bit, will have to see if I can sort that out.


'76 KZ400
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21 Apr 2024 16:28 #897964 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)
Lots of slop in the throttle before the engine revs up and slowly returns to idle are signs of problems. A throttle cable on the verge of failure could cause both. There could be other causes, but considering the rest of the bike, I’ll bet on this one.

The closing cable is not strictly necessary if everything else works perfectly, but the the possibility of having the throttle stuck wide open in traffic seems like enough reason to spend a few dollars on new cables.

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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21 Apr 2024 16:39 #897965 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Ya it's going on the list, already had to replace the tach cable as it felt off and then fell apart.  The remaining throttle cable does look a little spicy at the connection point so I was going to just see about lubing it but probably better of just replacing it.

'76 KZ400

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22 Apr 2024 10:24 #897978 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Couple dumb questions, but how does one replace that cable? Obviously the bar side just comes off with the switch mechanism but what about the other end? Need to pull the tank for access to where it connects to the carbs?

Second, looking on Z1 and seeing a reference to using shorter cables potentially, is that what I need now with the bar change? If so how short? Or how would I measure?

Thanks

'76 KZ400

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22 Apr 2024 17:58 - 22 Apr 2024 18:06 #897993 by TexasKZ
Replied by TexasKZ on topic How to mount clip-ons? ('76 KZ400)
The cables attach to the carbs in essentially the same was as to the throttle. Yes, the tank needs to come off.

Shorter cables? Maybe. Does the current one seem too long?

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
Last edit: 22 Apr 2024 18:06 by TexasKZ.
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23 Apr 2024 04:22 #898008 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Thanks and I'd say the cables could be an inch or two shorter without having a problem.  Could just be that the ones that's on there is old and it seems all the manuvering to get it on the new bars caused it to snap the connection before the metal bend piece that leads into the throttle switch. To be clear the cable didn't snap, just the shroud or whatever you'd call it, and only at the connection point to the metal bend piece.

'76 KZ400

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06 May 2024 11:31 - 06 May 2024 11:58 #898557 by ThatYeti
Replied by ThatYeti on topic How to mount clip-ons? ('76 KZ400)
Correction, wrong post.

'76 KZ400
Last edit: 06 May 2024 11:58 by ThatYeti.

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