Resurection of a KZ650

I could sure use some help. I am still trying to get this 79 KZ650 going. Here's the bike history. 5600 miles, PO parked it after carbs leaked in Spring of 95. I bought it and pulled the carbs, cleaned with simple green and aerosol carb cleaner. OK... start up time.

Bike runs with choke on. Throttle not very responsive. As I sit on the bike, left two
exhaust pipes get hot, right two are warm and can be touched. I pulled the #4 wire and it has spark.

What the heck are the possibilities? Still a fuel issue? The carbs were very gummy. I cleaned out what I could see.

Paul

did you remove all of the jets to clean them and poke them through with a tiny wire etc?

Welcome to KZr Paul.

It's likely that you still have a fuel delivery problem.

If you were to hook up a hose to each float bowl drain and loosen the drain screws, do they all flow at the same rate and drain the same amount of fuel?

Did you blow out the carb passages with compressed air when you removed the jets (you did remove the jets for cleaning, right?) to clean everything up?

Are all vacuum and fuel hoses in good condition, and were they re-installed properly (ie: not pinched, and installed on the correct fittings) and securely?

Are the vacuum caps that go on the intake manifold fittings still there, and are they in good shape (ie: snug, and not rock-hard or showing signs of cracking from heat/age)?

Thanks for the reply. I, too, think it's still fuel. Vacuum caps? Where are these? It does seem like it's not getting enough fuel.

Paul

The rubber vacuum caps go on the brass fittings that are on the intake manifolds/carb holders (shown in pic below) which mount the carbs to the engine, and if missing will cause a vacuum leak and make the engine run lean on fuel.



Post edited by: RetroRiceRocketRider, at: 2007/08/25 14:02

When I pull the carbs, there seems to be enough gas in the bowl but it's not being pulled in. Could that be vacuum? Could those reeds be stuck open. Where does the vacuum come from?

Thanks,

Paul

For reference, here's a copy from Kawasaki.com parts diagram of the 79KZ650 carb, together with the parts names listed.

Appears two carb versions were available -- one with pilot screw on the side and another with pilot screw from the bottom. Which version is applicable here?

Regarding source of vacuum (over-simplified), the engine sucks in fuel-air mixture from the carb.





Ref # Part # Description Qty Spec #
1 16005-027
Add to pick list TOP,MIXING CHAMBER 4 4
1 16005-027
Add to pick list TOP,MIXING CHAMBER 4
4 16019-031
Add to pick list GASKET,CHAMBER TOP 4 4
4 16019-031
Add to pick list GASKET,CHAMBER TOP 4
5 16003-013
Add to pick list NUT,5MM 4 4
5 16003-013
Add to pick list NUT,5MM 4
6 461F0500
Add to pick list WASHER SPRING 5MM 8 8
6 461F0500
Add to pick list WASHER SPRING 5MM 8
7 16039-016
Add to pick list WASHER,PLAIN 4 4
7 16039-016
Add to pick list WASHER,PLAIN 4
8 16046-012
Add to pick list SCREW,SLOTTED 4 4
8 16046-012
Add to pick list SCREW,SLOTTED 4
9 16057-002
Add to pick list SEAT,SPRING 4 4
9 16057-002
Add to pick list SEAT,SPRING 4
10 16040-026
Add to pick list SPRING 4 4
10 16040-026
Add to pick list SPRING 4
11 16067-006
Add to pick list BOLT,HEX HEAD,5X14 4 4
11 16067-006
Add to pick list BOLT,HEX HEAD,5X14 4
12 39075-1001
Add to pick list LEVER,THROTTLE 4 4
12 39075-1001
Add to pick list LEVER,THROTTLE 4
13 16033-031
Add to pick list SCREW,PAN HEAD,3X14 8 8
13 16033-031
Add to pick list SCREW,PAN HEAD,3X14 8
14 16007-028
Add to pick list BRACKET,THROTTLE VALV 4 (for 16001-272)
14 16007-028
Add to pick list BRACKET,THROTTLE VALV 4 (for 16001-1020)
14 16007-028
Add to pick list BRACKET,THROTTLE VALV 4 (for 16001-1022)
14 16007-028
Add to pick list BRACKET,THROTTLE VALV 4 (for 16001-1069)
14 39184-1001
Add to pick list BRACKET,THROTTLE VALV 0 4
14 39184-1001
Add to pick list BRACKET,THROTTLE VALV 4 4
14 39184-1001
Add to pick list BRACKET,THROTTLE VALV 4
15 16008-010
Add to pick list CIRCLIP 4 4
15 16008-010
Add to pick list CIRCLIP 4
16 16009-071
Add to pick list JET NEEDLE,5DL3 4 (for 16001-272)
16 16009-071
Add to pick list JET NEEDLE,5DL3 4 (for 16001-1020)
16 16009-071
Add to pick list JET NEEDLE,5DL3 4 (for 16001-1022)
16 16009-1013
Add to pick list JET NEEDLE,5CN15 4 (for 16001-1069)
16 16009-1015
Add to pick list JET NEEDLE,5CL10 4 (for 16001-1026)
16 16009-1029
Add to pick list JET NEEDLE,5CL16 0 4
16 16009-1029
Add to pick list JET NEEDLE,5CL16 4
17 16025-1006
Add to pick list VALVE,THROTTLE 4 (for 16001-1020)
17 16025-1006
Add to pick list VALVE,THROTTLE 4 (for 16001-1022)
17 16025-1006
Add to pick list VALVE,THROTTLE 4 (for 16001-1069)
17 16025-1016
Add to pick list VALVE,THROTTLE,CA2.0 4 (for 16001-1026)
17 16025-1025
Add to pick list VALVE,THROTTLE,CA1.75 0 4
17 16025-1025
Add to pick list VALVE,THROTTLE,CA1.75 4
18 16076-003
Add to pick list CIRCLIP 4 4
18 16076-003
Add to pick list CIRCLIP 4
19 16073-014
Add to pick list COLLAR 4 4
19 16073-014
Add to pick list COLLAR 4
20 16039-015
Add to pick list CAP,STARTER PLUNGER 4 4
20 16039-015
Add to pick list CAP,STARTER PLUNGER 4
21 16012-015
Add to pick list CAP,STARTER PLUNGER 4 4
21 16012-015
Add to pick list CAP,STARTER PLUNGER 4
22 670B1509
Add to pick list "O" RING,9MM 4 4
22 670B1509
Add to pick list "O" RING,9MM 4
23 16013-008
Add to pick list SPRING,STARTER PLUG 4 4
23 16013-008
Add to pick list SPRING,STARTER PLUG 4
24 16016-021
Add to pick list PLUNGER,STARTER 4 4
24 16016-021
Add to pick list PLUNGER,STARTER 4
25 16017-096
Add to pick list NEEDLE JET,O-8 4 (for 16001-272)
25 16017-096
Add to pick list NEEDLE JET,O-8 4 (for 16001-1020)
25 16017-096
Add to pick list NEEDLE JET,O-8 4 (for 16001-1022)
25 16017-1021
Add to pick list NEEDLE JET,0-4 4 (for 16001-1069)
25 16017-1018
Add to pick list NEEDLE JET,AO-7 4 (for 16001-1026)
25 16017-1034
Add to pick list NEEDLE JET,AO-5 0 4
25 16017-1034
Add to pick list NEEDLE JET,AO-5 4
26 16047-005
Add to pick list PIPE,BLEED 4 (for 16001-272)
26 16047-005
Add to pick list PIPE,BLEED 4 (for 16001-1020)
26 16047-005
Add to pick list PIPE,BLEED 4 (for 16001-1022)
26 16047-005
Add to pick list PIPE,BLEED 4 (for 16001-1069)
26 16047-005
Add to pick list PIPE,BLEED 4 (for 16001-1026)
26 49122-1006
Add to pick list PIPE,BLEED 0 4
26 49122-1006
Add to pick list PIPE,BLEED 4
27 16038-016
Add to pick list "0" RING,MAIN JET COV 8 8
27 16038-016
Add to pick list "0" RING,MAIN JET COV 8
28 92063-1028
Add to pick list MAIN JET,#A102.5 4 (for 16001-272)
28 92063-1028
Add to pick list MAIN JET,#A102.5 4 (for 16001-1020)
28 92063-1028
Add to pick list MAIN JET,#A102.5 4 (for 16001-1022)
28 92063-1028
Add to pick list MAIN JET,#A102.5 4 (for 16001-1069)
28 92063-1029
Add to pick list MAIN JET,#A90R 4 (for 16001-1026)
28 92063-1035
Add to pick list MAIN JET,#A97.5R 0 4
28 92063-1035
Add to pick list MAIN JET,#A97.5R 4
28 92063-1033
Add to pick list MAIN JET,#A100 4 4
28 92063-1033
Add to pick list MAIN JET,#A100 4
28 92063-1042
Add to pick list MAIN JET,#A105R 4 4
28 92063-1042
Add to pick list MAIN JET,#A105R 4
28 92063-073
Add to pick list JET-MAIN NO 107.5R 4 4
28 92063-073
Add to pick list JET-MAIN NO 107.5R 4
28 92063-068
Add to pick list MAIN JET NO 92.5R 4 4
28 92063-068
Add to pick list MAIN JET NO 92.5R 4
28 92063-1031
Add to pick list MAIN JET,#A95 4 4
28 92063-1031
Add to pick list MAIN JET,#A95 4
29 16022-016
Add to pick list SPRING,PILOT SCREW 4 (for 16001-272)
29 16022-016
Add to pick list SPRING,PILOT SCREW 4 (for 16001-1026)
30 16014-018
Add to pick list SCREW,PILOT ADJUSTING 4 (for 16001-272)
30 16014-018
Add to pick list SCREW,PILOT ADJUSTING 4 (for 16001-1026)
31 16038-024
Add to pick list "O" RING 4 (for 16001-272)
31 16038-024
Add to pick list "O" RING 4 (for 16001-1026)
32 16012-022
Add to pick list CAP,LIMTTER 4 (for 16001-1026)
32 11012-1041
Add to pick list CAP,LIMITER 4 (for 16001-1026)
33 16029-004
Add to pick list WASHER FLOAT VLV SEAT 4 4
33 16029-004
Add to pick list WASHER FLOAT VLV SEAT 4
34 16030-1001
Add to pick list FLOAT VALVE ASSY 4 4
34 16030-1001
Add to pick list FLOAT VALVE ASSY 4
35 92064-1018
Add to pick list PILOT JET,#A15 4 4
35 92064-1018
Add to pick list PILOT JET,#A15 4
36 92064-1019
Add to pick list PILOT JET,#A50 4 (for 16001-272)
36 92064-1019
Add to pick list PILOT JET,#A50 4 (for 16001-1026)
37 16031-031
Add to pick list FLOAT 4 4
37 16031-031
Add to pick list FLOAT 4
38 16032-003
Add to pick list FLOAT PIN 4 4
38 16032-003
Add to pick list FLOAT PIN 4
39 11009-1563
Add to pick list GASKET,FLOAT CHAMBER 4 4
39 11009-1563
Add to pick list GASKET,FLOAT CHAMBER 4
41 16049-007
Add to pick list SCREW,GUIDE 4 4
41 16049-007
Add to pick list SCREW,GUIDE 4
42 16014-1004
Add to pick list SCREW,PILOT ADJUSTING 0 4
42 16014-1004
Add to pick list SCREW,PILOT ADJUSTING 4 4
42 16014-1004
Add to pick list SCREW,PILOT ADJUSTING 0 4
42 16014-1004
Add to pick list SCREW,PILOT ADJUSTING 4
42 16014-1006
Add to pick list SCREW,AIR ADJUSTING 4 (for 16001-1069)
43 16038-022
Add to pick list "O" RING 4 (for 16001-1020)
43 16038-022
Add to pick list "O" RING 4 (for 16001-1022)
43 16038-022
Add to pick list "O" RING 4 (for 16001-1069)
44 16022-007
Add to pick list SPRING-THR STOP SCREW 4 (for 16001-1020)
44 16022-007
Add to pick list SPRING-THR STOP SCREW 4 (for 16001-1022)
44 16022-007
Add to pick list SPRING-THR STOP SCREW 4 (for 16001-1069)
45 13169-1107
Add to pick list PLATE,JET NEEDLE 0 4
45 13169-1107
Add to pick list PLATE,JET NEEDLE 4 4
45 13169-1107
Add to pick list PLATE,JET NEEDLE 4
46 92027-1103
Add to pick list RING,JET NEEDLE 0 4
46 92027-1103
Add to pick list RING,JET NEEDLE 4 4
46 92027-1103
Add to pick list RING,JET NEEDLE 4
47 92022-1024
Add to pick list WASHER,THROTTLE VALVE 0 4
47 92022-1024
Add to pick list WASHER,THROTTLE VALVE 4 4
47 92022-1024
Add to pick list WASHER,THROTTLE VALVE 4
48 92081-1072
Add to pick list SPRING,JET NEEDLE 0 4
48 92081-1072
Add to pick list SPRING,JET NEEDLE 4 4
48 92081-1072
Add to pick list SPRING,JET NEEDLE 4

Post edited by: Patton, at: 2007/08/25 21:09

Am guessing the carb pilot circuits (both air and fuel) are not perfectly "as-new" clean.

Would suggest getting a Factory shop/service manual if available (maybe eBay?) for your specific bike, or at least one of the aftermarket guides such as Chilton, Clymer or Haynes.

Also search the archives on KZRider for tons of KZ650 info on carbs and everything else.

Meanwhile, here's a pretty good general maintenance and repair guide.

Dan's

Good Luck!

Post edited by: Patton, at: 2007/08/25 22:07