1983 Kawasaki KZ1100 Shaft Carb Rebuild

Hey Everybody,

Couple of quick questions. On a 1983 Kawasaki KZ1100 Shaft I just picked up yesterday, I am rebuilding the carbs that sat with gas in them for 7 years (yikes...its like stinky molasses in there ) ... are there felt throttle shaft seals in there I have to worry about if I dip them?
Also, the enrichener plunger rubbers are all pretty hard (and broken!)... anyone know of a reasonable source for those new?
Thanks!
Skip

Aint she purty?

If Z1enterprises doesn't have what you need I'd tell you to start holdin' your breath on ebay.

I'm definitely no expert at carburetors though, sorry.

To the best of my knowledge there is no felt so dip away.

As for the "rubbers" Are you talking about the dust covers on the plunger shaft or the O-ring around the plunger(if it has one)? If the dust cover I never bother as most have been working fine for any number of years with them loose and broken. If the O-ring Z1 or elsewhere online.

There are rubber throttle shaft seals but the dip doesn't seem to negatively affect them so dip away.

The choke plunger "CAP-STARTER PLUNGER" are P/N 16012-1010 and are still available from Kawasaki... www.partzilla.com/parts/detail/kawasaki/KP-16012-1010.html

If you haven't seen this before it may help you. Don't replace the jets with junky "carb kit" parts. Recycle the high quality stock jets. zeus.mtsac.edu/~cliff/storage/gs/Mikuni_...Rebuild_Tutorial.pdf

Good luck.

Be very careful removing the pilot jet. Use a screwdriver that fits the slot correctly. You might even want to warm it up a little with a propane torch. The heads on them like to strip out easily and if you can drill out a pilot jet, you're better at it then I am.

Thanks for all of the replies. These carbs were *so* dirty that the slides were stuck... I could not move the throttle and just took a small pair of bolt cutters to the throttle cable (was going to replace it anyway) so I could get the carbs out. I have rebuilt maybe a dozen sets of various inline four carbs, and have NEVER seen anything that looked like these. The PO told me the bike sat for 7 years... looked more like 700 Which is a shame, because the carbs, after cleaning, looked like new, but I am afraid I screwed the pooch on the two middle carbs...stripped the top of the pilot jets, so I never got them out. As luck would have it, I had a relatively clean set of BS 34's in the parts pile; the pilots in both carbs were 37.5, the mains are 127.5 in the ones from the bike, so Ill swap those out with the 90's in the parts carbs. The little rubber bellows on the parts carbs are in good shape, The only thing Ill need to figure out then is the sizes for all of the tiny o-ring's on fuel t's, etc.

After much pounding, hammering, and chiseling I got the top of the master cylinder reservoir off. No front brakes, and when I first looked in the sight glass, was not encouraged by the fact that there was a 'level' that did not move when you moved the bars This master cylinder may be beyond rebuilding...