Removing carbs off an '81 KZ550 ltd

Hello, I just picked up an 81 KZ550 ltd as a project bike really cheap. The engine would not go past top dead center and I'm currently pulling it apart to see what damage, if any, there is. There are many good parts on this bike so the worst case scenario is that I could get my money back and more if I parted it out. I'd rather ride it though! So here's my question - I'm at the point where I need to take the carbs off so I can pull the head off to inspect things. Even moving the airbox back as far as it can go, I'm not seeing enough room to get the carbs off the engine head. I don't want to break anything so any hints and tips on pulling them off would be appreciated. Have a pic for those interested.

Cheers,
Mark

Welcome to the site!

The carbs are in there pretty tight but they will come out. The rubber boots on the back side of the carbs have probably hardened and over time, these will need to be removed. I usually try to collapse them and push them inside the air box, then you pull the carbs out of the front rubber mounts and bring them out the side.

Hope this helps!

Tom

Disconnect the boots from the back of the carbs then without putting holes in the boots push each (one at a time) past the intergrated flange back into the air box. You might have to take the air filter out. This should give the room needed. be ready to fight it a little just take your time and dont lose patience.

Try using a hair dryer to soften up the boots. They have hardened from exposure to ozone and will be difficult to flex while cold.

While at it, may wish to also consider new soft pliable air intake hoses from Z1 Enterprises.

Here's the link to click >
Z1E

Good Luck!

Thanks everyone for the great suggestions. As soon as I get a chance I'll give that a try.

Yup, hair dryer definitely helps.

1)Loosen the bolts holding the airbox in place so the airbox can move backward (it only moves slightly).
2)Make sure the carb holder clamps are super loose or better yet removed. (The carb holders have to open and deform a lot when the carbs are being pulled.)
3)Roll the spring clamps back to the air box.
4)Heat the airbox boots and carb holders with a hair dryer for a few minutes till they seem soft.
5)Sit on the bike and pull the carbs back towards the airbox.
6)Wiggle the carbs up and down as necesary.
7)Then tip the front up or down after they clear out of the front holders.
8)Then move them forward to clear out of the airbox boots.
9)Now they should snake out sideways.

Thanks for tip guys. They worked although I had to do some tugging to get the carbs off the header. The tip on getting the clamps super loose was the ticket. Now for the bad news. looks like I have damage to the head, valves and 2 pistons have holes through the top. I think my cylinder walls might be scratched up pretty good also. I think I want to puke. Would an '83 KZ550 GPZ motor work in an 81 KZ550 LTD frame? I see one on ebay.

mehall2 wrote:

Thanks for tip guys. They worked although I had to do some tugging to get the carbs off the header. The tip on getting the clamps super loose was the ticket. Now for the bad news. looks like I have damage to the head, valves and 2 pistons have holes through the top. I think my cylinder walls might be scratched up pretty good also. I think I want to puke. Would an '83 KZ550 GPZ motor work in an 81 KZ550 LTD frame? I see one on ebay.

hang in there....lots o help here...good luck....

mehall2 wrote:

Would an '83 KZ550 GPZ motor work in an 81 KZ550 LTD frame? I see one on ebay.

It will bolt in, but there are some issues. First, there is the oil-cooler which will need to be mounted to the frame somewhere.

Then there is the carburetor issue. The Carb holders on the old LTD engine will have to be modified and installed on the GPZ engine. The carbs will have to be rejetted also.

delete this please

I see an LTD motor. Kinda steep at $150.

And two others at $99. One looks real clean.

The 82 gpz (82 kz550H1) motor seems very steep at $350, and it looks pretty rough.

I Can't get the links to post here for some reason.