Kawasaki part # 16036015 (Pilot Jet Rubber Cap)

Did you hold up the pilot jet to the light to be sure the tiny orifice in the end is open? If not, please do so. That's the number one source of crappy running carbs.

I had a long time boat service repair buddy of mine help me, and he for sure messed with it for a while holding it up to the light and pushing different mm sized metal wires thru it.

I stand corrected. I was thinking those carbs were Mikuni's. Completely missed the part about them being Keihin's.

And I missed the different part # and the bracket in the first pic up top. I have never seen that bracket before or noticed it in parts diagrams. ..... which makes me think that it should be possible to make a simple metal bracket to hold one of those $2 black rubber plugs in place. .

I was missing the plugs from the carbs on my 1100 Spectre.

Whoever had worked on it before had removed them and never reinstalled them.

When I found out they were needed I improvised using lead fishing sinkers to seal teh bottom of the port, I was careful to keep them at the down into the bowl so the pilot jet wasn't sealed off.

I have since gotten the proper replacements, they are still in the bag the seller shipped them in.....

Ive been looking everywhere for the measurements for this rubber cap for my 75kz400D2, 76kz400d3 and 77kz400a1deluxe and I can not find it anywhere,,,

...and the one with the 1/4 piece of one left, I found out was thrown away. Any help would be greatly appreciated.

Here are the 3 different plugs Z1 offers:

www.z1enterprises.com/carb-rubber-passage-plug-5.html
www.z1enterprises.com/carb-rubber-passage-plug-4-gl1000-1.html
www.z1enterprises.com/carb-rubber-passage-plug-4-honda-1.html

If you have some calipers you can measure the hole size. For example, measure the ID of the hole and then look for a plug that's about 1mm larger around so it will press in and seal.

We have a similar issue on one of the Teikei carb models on the Gpz550's.

Having had some things printed on a 3-D printer, I'm not convinced it would be the best solution. At least not on the printers my friend had. When the plastic is laid down, it didn't come out very smooth. There were voids between the rows of plastic. Also, I'm not sure what plastic they used, but I think what you want is delrin (pure acetal).

I've had some acetal samples soaking in 10% ethanol gasoline at room temperature for several months and so far there hasn't been any discoloration or expansion.

I bought a $100 table-top toy lathe on ebay and made some plugs out of acetal rod. They turned out pretty good, but each one takes a while to make. If your dimensions match the ones I made for the TK26 carbs, I have a few spares.

s3.amazonaws.com/gpzweb/TK26mainPage/TK2.../TK26pilotPlugs.html

Ill be heading to the shop tomorrow to do some work, Ill get the measurements and give you a holler, thank you

Hello Jack_mills, maybe this is what you need.
Just found some bleeder rubber caps that fit tight into a valve guide (ID 7 mm), if your can measure the pilot jet hole i can do
some more investigations for a more suitable rubber plug.





Michael

I will for sure be at the shop where my 75 is today, and will take measurements. I greatly appreciate the help you guys are offering! I will get the measurements and post them on this thread later today.

Here are pics w the specs: