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TOPIC: kz650 bogging down after a few miles

kz650 bogging down after a few miles 06 Feb 2019 08:45 #798275

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I have a kz650 LTD with a touch under 30k miles. Everything is stock, except the pod filters, which I plan to replace with a stock airbox when I finish getting all the parts. The petcock is dead, so I just have a shutoff on the fuel line and leave the petcock on prime. There's an inline fuel filter right after the shutoff, I'm not sure if that is stock. The gas tank is a little rusty, so it is there to stop the rust from clogging the carbs.

The problem I am currently having is that after I ride a few miles the engine bogs down, even on highways going highway speed. If I sit a bit after it dies it will start right back up and be fine for a few miles.

I don't think it is vacuum locked, I cleaned the gas cap and there isn't a sucking noise when I remove the cap. Could the fuel filter be restricting flow just enough to empty the carbs? Or does this seem like old coils that don't work when they get hot? Or something else entirely.
'80 kz650 LTD
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kz650 bogging down after a few miles 06 Feb 2019 08:53 #798276

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Start with obvious fuel deficiencies. Clean tank. Replace fuel filter. Cut old filter apart and see what is in it .
I would next pull carbs and clean too. Do float bowls have drains you can pull to clear them of fuel and or debris ?
Sounds like you need to go thru and do a complete service / tune up
Dave
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kz650 bogging down after a few miles 06 Feb 2019 10:33 #798283

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Also make sure the fuel line is not kinked. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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kz650 bogging down after a few miles 06 Feb 2019 11:06 #798285

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The bowls do have drains to clean them up. I'll clean the tank and get a new filter. I really should do that anyway even if I had no issues. I'm trying to avoid messing with the carbs too much until I get the rest of the airbox pieces and slap that on there so I don't just have to tune it again.
'80 kz650 LTD

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kz650 bogging down after a few miles 06 Feb 2019 11:25 #798287

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If the petcock has a screen, treat it with care when cleaning it as a replacement screen may not be available. I'm assuming you plan on removing the petcock when cleaning the fuel tank.




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kz650 bogging down after a few miles 06 Feb 2019 14:45 #798295

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Have the valves been adjusted?
Steve
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kz650 bogging down after a few miles 06 Feb 2019 19:57 #798311

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Not since I have had it, which has been since December. I would not be surprised if it was long overdue.
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kz650 bogging down after a few miles 06 Feb 2019 20:03 #798312

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Start there before going to the carbs.
Steve
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kz650 bogging down after a few miles 06 Feb 2019 20:10 #798313

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I think that is beyond me at this point, what other symptoms would it cause?
'80 kz650 LTD

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kz650 bogging down after a few miles 06 Feb 2019 20:17 #798314

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How about burned valves and the death of the Bike? It's the most neglected or ignored of all tune up procedures. Many times a bike is sold by the cheap or lazy PO saying it just need carb adjustments.
Steve
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kz650 bogging down after a few miles 08 Feb 2019 07:29 #798356

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Checking the valve clearances is not really difficult, and certainly easier than carb tuning. Changing the shims is more involved, but doable with help from members here.

I would certainly look hard at the fuel filter. If it is a paper element, it may be for a pressurized system, and will cause the problems you describe. Toss it, and get a new one that you know is for a gravity feed system.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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kz650 bogging down after a few miles 08 Feb 2019 08:34 #798358

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I need to buy more tools before I can check valve clearances. I only have a small set of sockets and wrenches, which is a little lacking. I believe I will need a feeler gauge and something to set the torque the screws on the cover properly. Can you think of anything else?
'80 kz650 LTD

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kz650 bogging down after a few miles 08 Feb 2019 12:20 #798365

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It doesn't take very much. When you're ready we'll guide you through.
Steve
Z1b1000 1975 Z1b
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kz650 bogging down after a few miles 09 Feb 2019 10:00 #798397

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What year is it?
Start with simple things
I would rebuild the petcock and get rid of the inline filter and shut off first.
If your bike only runs on prime then you don't need the extra shut off, just turn it to on, and I may get some flack for saying this but if the filter in the petcock is clean and has no holes then you don't need an inline filter.
Some inline filters(not all) can clog up because they are too fine. any crud that goes through your system only needs to be smaller then your jets to get burned up.
If you rebuild the petcock correctly and run the vacuum hose to the right port the automatic shut off will work again.
78 KZ1000 A2A

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kz650 bogging down after a few miles 09 Feb 2019 17:07 #798410

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It's a 1980.

The vacuum hose on the petcock (no joke) has a golf tee stuffed in it. Theres a bunch of hoses from the carbs going to nowhere, so I'm gonna have to look up a schematic and figure out what is going on.
'80 kz650 LTD

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kz650 bogging down after a few miles 09 Feb 2019 17:11 #798411

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Does gas come out if you remove the TEE? All nipples on the carb holders need to be capped.
Steve
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kz650 bogging down after a few miles 09 Feb 2019 18:16 #798415

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I'm not sure. I have the gas tank off the bike, and the petcock and fuel sensor removed. I'm currently cursing myself for dumping pennies in the tank, since I'm having trouble removing them.

Also, does anyone know where I can get part 11039-003? Its part #8 here: www.kawasaki.com/Parts/PartsDiagram/144005/1978/KZ650-B2
Do I actually need it? Could I make one? Could I use something else?
'80 kz650 LTD

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kz650 bogging down after a few miles 10 Feb 2019 06:54 #798426

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You should put your bike info in your profile , it makes it easier to help
Do you have a Kawasaki shop manual?
if not here is the link to a 81, I don't know if it is the same as the 80 but it should be close
kzrider.com/modules/ServiceManuals/Kawas...l%20KZ650%201981.pdf

Page 3-2 shows the inside of the petcock, over time the wonderful ethanol added fuel we get these days will destroy the original O-rings also over time lacquer from old gas builds up if the bike sits.

don't worry about getting a syringe or vacuum gauge there are easier ways to check the system

78 KZ1000 A2A
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kz650 bogging down after a few miles 14 Feb 2019 14:48 #798668

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Well, I seem to have cleared up the fuel shortage issue, now fuel leaks from an air filter when I leave it on Prime. Ill have new seals for my petcock in probably tomorrow. I also got some vacuum line to actually connect the petcock, which should be pretty easy once I find where It connects in the shop manual. I might try and buy a physical copy, since that thing is a royal pain to flip through in pdf form.

EDIT:

I set up the petcock and got it all working, it still does leak gas from the air filter though if I leave it idle too long, but I went on a nice long ride and I did not bog down. I'm still going to look at the valves though just to be safe, and I should probably clean the carbs, since this overflow would indicate the carbs have something not quite right.

The previous owner did another weird thing: The hoses at the bottom of the carbs all go into a little can he has ziptied to the frame under the right side cover. Where should these hoses actually go to?
'80 kz650 LTD

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Last edit: by Cabbagio Redentor.

kz650 bogging down after a few miles 16 Feb 2019 14:18 #798785

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I figured out why the original owner had installed pod filters: He cut the battery cage, riveted some bent drawer glides onto it and stuffed a bigger battery in it. This then left not enough room for the airbox. I drilled out his rivets and I'm buying a smaller battery I can fit in the cage once I fix it. I am going with a smaller one, since the original dimension ones are all lead acid with the acid vent hoses and I don't really want that. Being as I have a kickstarter, I only really need something there to complete the circuit and power the lights while I start it.

I've been refurbishing my airbox boots with a soak in a 1:1 mix of 91% isopropyl alcohol and Methyl salicylate.

I need a nice warm day to remove the carbs to install the airbox now.
'80 kz650 LTD

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Last edit: by Cabbagio Redentor.
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