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Long drive killed engine? Carbs check out 06 Aug 2019 09:09 #808796

  • godzilla
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Hi,
Maybe a little far-fetched but have you tested so that the battery is fully charged and in god condition?
It could be a charging problem resulting in a weak spark.

Regards
Anders

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Long drive killed engine? Carbs check out 19 Aug 2019 17:53 #809504

  • newkzrider18
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OK overdue and long update.
Cleaned carbs AGAIN looking to make sure I could see through all the jets and those holes in the various pipes, sprayed through the carb body passageways as well.
Same problem. Hesitates with throttle.
No sticky floats.

So I ended up doing a compression test and it looks good. On the high side, (dry 170 left & right, wet 205 left & right), although the manual said "109-150 psi OR within 14 psi of eachother"....they are definitely within 14 psi of eachother, but not within the former range, so idk what the 'or' is about, but I'll probably clean the piston heads for good measure.

Anyway...I'm fairly certain now it is a carb adjustment problem.
I actually had it running and no blipping or hesitation, I could use the throttle however ONLY when the choke was fully used. If I tried to lower it at all, the bike hesitated and died like before.
Since all the fuel tests I did before checked out, I think there is some adjustment issue....

Would someone walk me through how to adjust the carbs?
I know the manual tells you to back out the pilot screw 2.75 turns then to change the idle adjuster until it is at appropriate range, but maybe because there are aftermarket exhaust on the bike the pilot srew amount of turns could be different?
And the shimming on the needle, it was at 3 before, and I changed it to 2, maybe I should go back.

Because I could at least get it to not hesitate when there was enough fuel, so it's pretty clear it is a fuel issue:
1) carbs clean (every single part)
2) floats not sticky
3) vacuum on petcock works
4) floats getting fuel = carb getting fuel
5) sliders are in working condition (air compression tested and thumb test)

Has to be an adjustment problem???
That's still so weird though, why would a long drive mess that up!?!?

Thanks if anyone reads this after so long!
1980 KZ 440 LTD Model A

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Long drive killed engine? Carbs check out 19 Aug 2019 18:12 #809507

  • TexasKZ
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Did you check the fuel level using the clear tube method described in the factory manual?

The fact that it runs better with the choke on is an indication of a very lean condition.
Fuel level is much too low.
Pilot circuit clogged.
Air leak.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Long drive killed engine? Carbs check out 19 Aug 2019 18:59 #809512

  • newkzrider18
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correct, it all points to a lean condition.
Yes I did the clear tube method and it is within specs.

It's just, there are already 3 washers on the thing. That already seems like a lot. I am weary to add more to fix the lean condition.
Don't think it would be the pilot circuit as stated the carbs have been thoroughly cleaned not once, but multiple times.
Maybe the air leak. Though I did change the carb boots recently and they have no cracks.
Any other places to look for an air leak?
1980 KZ 440 LTD Model A

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Long drive killed engine? Carbs check out 19 Aug 2019 20:28 #809520

  • baldy110
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Your carbs are still clogged / dirty. I know you said you cleaned them but if it only runs on choke the pilot circuit is clogged or you've got a massive vacuum leak which is unlikely. I've had to take apart and clean some carbs numerous times in the ultrasonic cleaner before they were actually clean.

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Long drive killed engine? Carbs check out 19 Aug 2019 20:46 #809521

  • Nessism
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newkzrider18 wrote: (bought bike used, also has aftermarket exhaust on it so maybe this was an adjustment?)
I don't have the pods, I made the custom air filter that's on this site.


I suspect this is at least part of the problem. The jetting needs are changed based on the different airbox and exhaust.

I'd put the needle back to stock and then slowly block off intake flow using tape over the filter element a little at a time to see if that helps clear up the running problems. Assuming that helps you will then know where to focus your efforts (jetting.)

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Long drive killed engine? Carbs check out 20 Aug 2019 02:59 #809524

  • godzilla
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Hello,

Have you checked the timing advancer unit so
its moves easily.

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Long drive killed engine? Carbs check out 20 Aug 2019 06:40 #809534

  • newkzrider18
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Timing advancer is good.
I'll try the tape method after cleaning the pilot circuit. Unfortunately when I bought the bike I took it to a used parts store to see if they had the original air box (obviously they didn't since I made one) and we checked to see if they made a jetting kit for my bike but they don't :[

As for carb cleaning here's what I know:
I can see through ALL of the following (any holes on them included)
1) Pilot Jet
2) Primary Main Jet
3) Bleeder Pipe
4) Secondary Main Jet
5) Needle Jet Holder

Since I can see through all their various respective parts, I think it is safe to assume those parts are clean.
that being said, is there a passageway I can run wire through to see if it is clogged, or squirt something and it should come out somewhere?
Manual wouldn't/doesn't give any information on passageways.

Thanks for all the help everyone
1980 KZ 440 LTD Model A

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Long drive killed engine? Carbs check out 20 Aug 2019 06:52 #809536

  • TexasKZ
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Taping off the intakes seems like an easy way to confirm a fuel mixture problem. I also suspect (please pardon me if I already said this) that placing three washers under the needles was a lazy way to compensate for pilot and main jets that are way too small.
Seems like Patton has recently posted a diagram of the various passages in the carbs. You might find it by looking at his recent posts.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Long drive killed engine? Carbs check out 20 Aug 2019 07:04 #809539

  • newkzrider18
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I actually think I remember seeing a post of his, so I know what you're referring to.
Yeah I don't like the washers method either, however (since there is no kit) I'm not experienced enough to know exactly what size jets I need.
I would rather re-jet, but don't want to do it wrong and mess up the performance even more. Advice on that?
1980 KZ 440 LTD Model A

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Long drive killed engine? Carbs check out 20 Aug 2019 07:04 #809540

  • newkzrider18
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And definitely don't feel comfortable drilling the jets like some suggest!
1980 KZ 440 LTD Model A

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Long drive killed engine? Carbs check out 20 Aug 2019 07:10 #809541

  • SWest
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Pic of the plugs?
Steve

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