Problems after carb teardown and clean (again)

I have an 81 KZ650 CSR that has been only running on 3 cylinders, so I tore down and soaked them in Berrymans Carb dip. It made an amazing difference! I am now running on all 4, but am still having some of the same problems. I Checked and adjusted the float height too. When I crack the throttle from a load, like I am leaving a Stop sign, not on the throttle much, but trying to accelerate to 20 mph say, it bogs down and wants to die, I have to pump the throttle to keep it alive. Will doing a full vacuum sync solve a problem like this?

It just occurred to me, since there are no '81 specific carburetor kits, I bought 1978 kits from carbkitcapital.com . All the seals and gaskets were the same, but are the jets different? What are the jet sizes on a 78? The original '81 jets are 92.5 main and 15 pilot. Could this be the root of my issues? If not, any suggestions?

Im no expert on 650 carbs but aren't the 81 carbs the cv style,or did they change the cv carbs later?
Well just checked looks like they switched in 82,disregard and carry on.

ShouterVW wrote: I have an 81 KZ650 CSR that has been only running on 3 cylinders, so I tore down and soaked them in Berrymans Carb dip. It made an amazing difference! I am now running on all 4, but am still having some of the same problems. I Checked and adjusted the float height too. When I crack the throttle from a load, like I am leaving a Stop sign, not on the throttle much, but trying to accelerate to 20 mph say, it bogs down and wants to die, I have to pump the throttle to keep it alive. Will doing a full vacuum sync solve a problem like this?

It just occurred to me, since there are no '81 specific carburetor kits, I bought 1978 kits from carbkitcapital.com . All the seals and gaskets were the same, but are the jets different? What are the jet sizes on a 78? The original '81 jets are 92.5 main and 15 pilot. Could this be the root of my issues? If not, any suggestions?

www.kzrider.com/forum/11-projects/449519...t=20&start=20#579202

Patton wrote:

ShouterVW wrote: Okay I got the carbs reassembled. Checked and adjusted the float height, and threw them back on....

If not already done, the clear tube test is necessary to verify that the fuel levels are within spec.

The clear tube test shows the true actual fuel level, which is referred to in the factory manuals as the "service" fuel level.

Good Fortune!

I did the clear tube test. It was a couple mm below carb body on all 4

Pilot circuits may require better cleaning.
Here's one method.
Wear eye protection when spraying, because the spray always backfires. Always.



Good Fortune!

Did that as well. More than once. All circuits come out clean.

Does turning the pilot adjustment screw on carb #1 have a noticeable effect on idle rpm?

And same result with each of the other carbs?

If not, there's usually something still wrong inside the carb.

The pilot jet must of course be removed to properly clean it.
Should be able to hold the jet up the light and with naked eye see through a perfectly round orifice.

Am thinking poor sync might contribute to the bogging at pull-away, but that poor sync isn't the primary reason.

Might require brand new pilot jets, especially if there's some doubt as to whether the existing jets might have been "drilled out."

Also, the pointed end of the pilot adjustment screw must be in good condition and not "grooved" or otherwise damaged which could impair its function toward regulating volume of air allowed into the pilot mixture.

Good Fortune!

The jets are new with the carburetor kits bought from carbkitcapital . The kit is for a 1978 kz650 with jets. Do I have wrong jet sizes? And yes I bought float bowl gaskets with the hole for the accelerator circuit (which is in working order). When I turn the air screws in on 1 yes it does make the bike want to die.

What size are in the Carbs Now? And what sizes Were in there Before, the old jets?
What did you replace in the rebuild kit? Needles? Pilots? Mains? List out what you had and have now for sizes. Do you have "Pods" or the Stock Air-Box?

According to kawasaki.com, PILOT JET #A15, Part No. 92064-1018, remains "Active," which means supposedly available through Kawasaki dealerships.

Btw, are all valve clearances within specs?

Has a compression test been recently performed?

Are fat blue sparks visible on every plug?

Has function of the advancer been verified under a timing light?

Good Fortune!

Is ignition timing spot on?

At idle rpm, the F mark should align with the case mark.






Good Fortune!

ShouterVW wrote: I have an 81 KZ650 CSR that has been only running on 3 cylinders, so I tore down and soaked them in Berrymans Carb dip. It made an amazing difference! I am now running on all 4, but am still having some of the same problems. I Checked and adjusted the float height too. When I crack the throttle from a load, like I am leaving a Stop sign, not on the throttle much, but trying to accelerate to 20 mph say, it bogs down and wants to die, I have to pump the throttle to keep it alive. Will doing a full vacuum sync solve a problem like this?

It just occurred to me, since there are no '81 specific carburetor kits, I bought 1978 kits from carbkitcapital.com . All the seals and gaskets were the same, but are the jets different? What are the jet sizes on a 78? The original '81 jets are 92.5 main and 15 pilot. Could this be the root of my issues? If not, any suggestions?

Shouter,
Maybe this will help. It's a list of the carb setups we have on the 650 site. You don't say what intake or exhaust you run, or did I miss this?

forums.kz650.info/index.php?topic=1853.0

VM24 carbs unless otherwise stated.
Not sure of the accuracy or if they're still running the same:

rstnick (Rob) '78C 112.5 mains 15 pilot air screws 1 1/8 turns out Kerker 4>1 K&N in air box
jeffw '77 B1 VM24 with accel pump, 97.5 Mains 15 Pilot Needle Clip to Position 4 Pods & V&H Exhaust 5000 ft elevation
Charlie '77 C1 107.5 mains and 17.5 pilots stock needle position V&H 4>1 Stock filter and air box
mpowell '77B 105 main 17.5 pilot needle middle clip V&H 4>1 K&N in air box
onkelB '77B 112.5 main 15 pilot needle 4th groove (2nd from bottom -stock) Harris 4>1 air box stock filter
kzKat '79D 97.5 main 17.5 pilot needle 5th groove kerker 4>1 pods
Melvis '78D VM29 smoothbores 117.5 main 17.5 pilot needle 3rd groove
MadMac74 '78C 110 mains 17.5 pilot needle 3rd groove Mac 4>1 K&N in air box
'80F 97.5 main 15 pilot stock exhaust air box
'77B 102.5 main 17.5 pilot needle 3rd groove Mac 4>1 air box
'80F 107.5 main 15 pilot needle at bottom kerker 4>1 pods
anarki '77B1 115 mains 17.5 pilots needle in 4th groove emgo pods Mac 4>1
anarki '81 CSR 115 mains 17.5 pilots needle in 4th groove emgo pods
anarki '77B1 with VM26 117.5 mains 17.5 pilots K&N pods Mac 4>1
OKC_Kent '78B2 102.5 mains 15 pilots needle at 4th Stock exhaust Uni filter in air box
HerrDeacon '78D1 118 mains 17.5 pilots needle at 4th pod filters
spudbuddy '78B2 with VM22 95 mains 15 pilots needle at 5th Stock air box Kerker 4>1
Mark Wing 810CC '77C VM29 smoothbores 122.5 mains 17.5 pilots Yosh 4>1
Dzawack '78D1 VM22 102.5 mains 17.5 pilots needle at 4th pod filters 4>1
80kawi650 '80E1 115 mains 17.5 pilots pod filters stock exhaust
bcfd392 '79D2 115 mains 17.5 pilots needle at 4th K&N pods 4>1
Squadrider '79C3 with accel pump 112.5 mains 20 pilots pods 4>1
SteveMS '80F1 102.5 mains 15 pilots needle at 3 stock air box 4>1
Qdude '77C 120 mains 17.5 pilot needle unmoved on pods and a Super-Trap eight plate baffled 4 > 1
Qdude '77C 102.5 mains 15 pilots needle unmoved on pods and a Kerker un baffled 4 > 1 (these carbs have the screw on the underside, I have not messed with these carbs other than to rebuild them with the Kawasaki rebuild kits. I did this in 2007 back when my understanding of these things was much less than it is now. I have no idea how the bike is running as well as it is on the stock setup with pods and 4 > 1...).
Seymore '78 B2A VM22ss Mains-90, Pilots-15, Over the pilots-50