KZ1100 CASS delete + carb clean causing WOT over-rev?

1983 KZ1100 A; shaft model -- Just did a carb rebuild; sonic cleaned everything and blew it out, new mains, pilots and fuel needles, new air adjustment screws, the works. Bench sync + vacuum sync on gauges. Also deleted the CASS system with blocker plates. I have the pilot air screws at 2 turns out and get a good idle and low end acceleration but when I accelerate WOT the revs on the engine jump pretty drastically without the corresponding speed gain; I can still get it up to top speed pretty quickly by giving it small throttle increases but WOT gives the crazy rev jump.

I replaced the jets with all the same sizes, no other fuel system changes.

Could the CASS delete have affected my main jetting? Carb sync issues? Don't have my pilot screws set correctly? I'm stumped.

Have you checked the clutch cable adjustments? Are you using energy conserving automotive engine oil? What you describe are symptoms of a slipping clutch.

Thanks Texas! I'll check it and report back. No special oil, just standard 10-W40.

Are they aftermarket jets? Might be better off cleaning and using the stock ones. Any other changes?
Steve

If it is not motorcycle specific oil, or Diesel engine oil, it probably has the energy conserving logo on the bottle somewhere. Those friction modifiers can cause wet clutches to slip.

Mr.Wizard wrote:
No special oil, just standard 10-W40.

You Need a 10-W40 oil with JASO MA/MB Oil Specifications for wet cluch engines.
Automotive oils (dry clutch) let your clutch slip´s on acceleration.

Ok, I'll bite what is the CASS?

I think he´s talking about by-passing the (C)leaning (A)ir (S)ucition (S)ystem.

Scirocco wrote:

Mr.Wizard wrote:
No special oil, just standard 10-W40.

You Need a 10-W40 oil with JASO MA/MB Oil Specifications for wet cluch engines.
Automotive oils (dry clutch) let your clutch slip´s on acceleration.

I've used various types of diesel oil w/o JASCO MA cert and all worked perfectly. The problem type oil is as TexasKZ states, the Energy Conserving type.

There is absolutely zero gain in removing the CAS system It uses zero HP to operate, and by drawing filtered air into the exhaust system, it causes a after burn of unburnt hydrocarbons in the exhaust system. That said.. there are plenty of things that are done intentionally that DO rob these bikes of HP and cause / give poor performance, none being the CAS.
As everyone has stated, your clutch is slipping. I run Rotella T-4 lately.. and may switch back to T-6 synthetic at a later date. Do not use car oil in a motorcycle with a wet clutch. As you are now experiencing with good old 10-40.
.

Definitely the clutch, I pulled the clutch cover and I don't think they've been replaced in 30k, the slipping was getting much more pronounced riding yesterday. Thanks for all the good information on the oil req's, I wasn't ever aware of that! I removed the CASS for aesthetic purposes, I've read all the differing opinions on (lack of) performance gains.

I can definitely understand wanting to remove extra stuff. The CAS system is hidden under the tank, so little shows aesthetically that removal would be a moot point IMO, but you may lighten the bike a few ounces removing the valve and hoses and plugging the filtered air hole in the air box.

Yep, I have had the slipping clutch blues myself. My bike is almost 40, and the clutch plates were not getting any younger. I tried several times unsuccessfully to clean and deglaze them, new springs etc, but nothing seemed to help much until I just bit the bullet and bought brand new OEM steels and frictions from Partzilla. I paid full list price with frt that totaled somewhere around ~160.00 delivered. Better deals can be had, but I did not find out until after some forum members pointed it out.

These are my originals after soaking in citrus degreaser, scrubbing , rinse and dry. They looked great, yet couldn't handle the HP.


I can tell you one thing, My clutch does NOT slip when I pour on the coals NOW. I's almost the opposite that it used to be, and sometimes sticks after sitting a few days.. It wants to GO. I just kick it into gear and it breaks loose after it attempts to buck me off YeHa! . lol