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1981 KZ550 D1 GPZ550 won't start 10 Jan 2024 18:44 #893861

  • TexasKZ
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Between now and then it would be a good idea to confirm what jets and needles are in the carbs. The fsm lists the stock numbers.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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1981 KZ550 D1 GPZ550 won't start 10 Jan 2024 19:06 #893862

  • RonG
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Hello TexasKZ:
How can I tell what jets are needles are in the carbs? Maybe its a dumb question, but I don't know how to identify them.
Ron

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1981 KZ550 D1 GPZ550 won't start 10 Jan 2024 19:37 #893864

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They should have a code stamped on them.

Once the carbs are spotlessly clean, all the gaskets a orings renewed, the jets and needles are sorted, the fuel levels are correct and the basic bench synchronization is done, you will need to do the fine tuning. 
So far, the only tools needed are a couple of wrenches and high quality, tight fitting JIS screwdrivers, and a short length of clear tubing. The only specialty tool needed is for the final synchronization. I use one of these. www.ocdmachine.com/carbtune-pro-4-column.html
 
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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1981 KZ550 D1 GPZ550 won't start 21 Jan 2024 13:18 #894273

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OK so I'm going to try to go from pods (the bike was tuned for pods) back to the original airbox. I know these questions probably sound dumb but that's where I'm at. I ordered two carb kits from Z1 (they've arrived) mostly because I needed the fuel bowl gaskets. But now, when going back to the original airbox, should I replace all the jets currently in the carbs with these new jets from the kits? I'm assuming that gets me back to the original airbox jets? In that case I'll need to order two more kits and the O rings, although I don't really understand which O rings I need (some appear to be in the kits, but I understand there is a bunch more I think in the fuel lines feeding the 4 carbs?). So, at this point I'm wondering, should I get another 2 carb kits then replace all the carb parts with what is in the kits. I also need to obtain a few more airbox parts like the brackets that hold it, and the springs that go around the rubber air tunnels connecting the airbox to the carbs. 
Ron

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1981 KZ550 D1 GPZ550 won't start 21 Jan 2024 14:48 #894279

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Before you replace any jets, you need to find out what is in there. The jets and the needles will  have numbers stamped on them. The factory jetting is listed in the fsm. Aftermarket jets often use their own system of numbering just to complicate matters. 
If you look at the exploded parts diagrams on Partzilla or CMSNL, you can see where all those pesky orings go. You will also want to insure that all four choke plates are present.

The springs, ducts and that bracket show as still available from Kawasaki, by way of Partzilla.
www.partzilla.com/catalog/kawasaki/motor...kz550-d1/air-cleaner

You must sign in to see the price of the ducts. You may want to be seated before you do that.

 
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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1981 KZ550 D1 GPZ550 won't start 26 Mar 2024 09:21 #896907

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I'm finally getting these carbs back together after a thorough cleaning. Question: the top part of the carb with the throttle shaft that rotates, how it is lubricated? Do I need to add lubricant to the top part of the carb assembly? Thanks.
Ron
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