1981 KZ550A2 Update

When they are installed in the carb body, the pins can't walk all the way out. The carb body only lets the pins come out about a mm or two. So a loose pin, by itself is not an immediate problem since the flaps (if not broken) will not be released. The problem is that when the pin walks out, the flap doesn't seal.

What causes the flaps to get sucked into the motor is when the hinge curls on the flaps break off. Maybe a loose pin aggravates that, but it's very common to find all of the pins loose, but yet have all four flaps in tact.

The pins have probably been loose for many many years. I first noticed it when I got my first 550 ( back in 1993, I think).

So as long as the hinge curls look fine with a magnifying glass, you should be ok. What to look for is a faint line on the hinge curl parallel with the pin. That indicates a possible crack or weak spot on the hinge curl.

The plate assembly is pot metal. Even Allumalloy and other brands of that type of repair material doesn't do well with the pot metal. I just use a sharp punch near the pin hole, to grab the pin a little bit when staking it. Don't hit too hard as the metal is brittle. And don't worry too much if they work loose. It's more important to not break the plate assembly, as there are few to none on ebay (I haven't checked in awhile). Usually you end up having to buy a whole rack.

They had vibrated enough to srum up the the pin exit hole. Looked like they were previously staked badly. No way to take a hammer to it easily with out further damage. i covered the pin ends with a smidge of super glue and will put em back in. Each pin when fully positioned was inset about a 1/16th of an inch so I think the glue there will be fine at keeping the pins in place. All the fins where in great shape, no bends or fatigue and I did check the curls. Damn little springs are a pain in the ass. Any way, it will be too cold for garage start gonna be near or below zero for a low the next few days here, but I am looking forward to shoring up my plugs, wires and coil connections. She's gonna purr. Peace. R

Super glue should work ok, or epoxy as you mentioned.

NGK plugs and wires together and installed. Choke flaps back in and carb tops on. Pics coming. Out now had to get on. It's 25 may try a cold start tonight. Either way the caps and wire ls look great and will work well. R

Looks good.

EDIT: Nevermind, I see it.

With the exception of a new seat cover left, I declare the bike ready to roll. i did not end up removing the engine from the frame. So, it has a patina of age. I have inspected and fixed all systems. Rust removal (a lot), new tires, new wires and caps, gas tank cleaned and sealed, ignition/electrical system complete gone through, carbs cleaned and sorted, airbox ducts, fork seals and oil, master cylinder rebuild, petcock rebuild, brake pads, grease and lube, misc. orings and rubbers, new oil and filter. With only 3500 miles this thing is gonna be great when spring like weather arrives, or at least until the snow clears and it's above freezing. Thanks for the boat loads of help from many of you on the forum. I could not have done it by myself. Happy Motoring. R

Here is a vid of the much better running bike. Let is perk, it's in 1080 60p.



R

It's not working. Youtube says it's still processing.
Steve

Let it perk, make some popcorn - great video

WOOOHOOO!!!! :woohoo: :woohoo: :woohoo: :woohoo:

I bet you can hardly wait for some better weather so you can get everything perfectly dialed in.

I was tempted to push to the main road. Its 20 degrees here. The drive is 1/8 mile or so completely snow covered. I am getting a little smarter as I age. Just a little helps, I need all I can get. :lol: Very psyched to ride it. Big contrast to my 1500 Vulcan which I also love. R

Got a set of vacuum gauges? I saw that glob of snow on the floor. It's cold here but not like THAT. Must be tearing you apart not being able to ride it. Don't chance it, you'll ride soon.
Steve

Yes. When I get some better ambient temps will fine synch with the gauges I have. It was 6 this am. R