KZ650 - STILL not possible for WOT :-(

Dear KZ Specialists;
I become crazy with tuning my baby for WOT performance...
This is my last thread regarding this issue:
www.kzrider.com/forum/3-carburetor/61402...ot-possible-full-rpm

At that time i have thought to have solved that problem, but it wasn´t.
It is still present, much less as back then, but very unconfortable.
5th gear, arround 8 to 8.5k - means approx. 155km/h it starts only at full WOT: brrrrrrrrrrrrr, b,b b,brrrrrrrrrrrrrrr..... and so on. Minimum reduction of throttle way (to 7/ and she pulls again strongt. But have same issue if i hit WOT even on 4th at 4k. Engine starts to become louder and the jerking stats. If i roll the throttle slower to 7/8 she pulls strong. Only full open slides leads to that problem.
EDIT: Throttle Stop on Carb is screwed more or less full way in to avoid to far open slides!

Current jetting (and i have opened that carbs 50 times and more):
17.5 Pilot
Idle perfect, checked with colortune and pefectly synced carbs; No leaks in boots;
K&N Pods with Air reduction from ZED;
Reworked Joke Plungers from ZED;
112 Main (115, 117,5 makes it more worse); Same for 102 to 110);
Original and new Needle Jet (0-;
Jet Needle (Keyster Y63 - same as Mikuni 5DL3) in much richest position + 2 .6mm Shims; Crazy, but this leads to perfect accerleration; Ask Mikuni for another (richer) Needle?
Floats perfectly set with clear tube; No leaks;
Original Slides;
Carbs Supersonic cleaned lot of times;
No restriction in fuel - no fuel filter, new pedcock; Fuel Cap Vent is working; Same with open Fuel Cap;
Hint: Using Joke at WOT changes nothing;

So i am at the end of my knowledge;
Because changing Main Jets is not leading to a big change i am start to think if the problem is from the electric?
Dyna black 5ohm coils with Dyna Carbon cables (resistor); Cooper cables from Dyna leads to inteferences into my electronic system (Tacho doing crazy things);
Green coils no difference; Maximum Voltage (14,6V) from LiiON Battery on Coils;
All Wires New;
PLUGS: Yesterday i have seen, that i run BR8 NGK´s (with resistor); Changed toaday to B7ES w/o resistor. Nicer idle, but no change at WOT;
Will receive tomorrow B8 and B9ES; Think will not change WOT proble, but i give a try.
Generator is old and not changed; But charging system is working pefectly with new Regulator for LiIon Battery. So think this is no problem.
Ignition: ACCENT (German manufacturer) - digital; Had at beginning troubles with that thing (Engine failure when hot - very funny to detect that ignition was faulty); However, received new Ignition which works; Should i change to Dyna S?
Advance is working super soft and Timing checked with strobe.

Done quick compression test (700cc Pistons; Changed before 5.000km); New Valves, Seats and Seals; Valves in tolerance before 2.000km.
Plugs removed, Enginge was more or less cold, WOT:
1.: 9.5bar; 2.: 9.7bar; 3.: 10.2bar; 4.: 10.5bar;
EDIT: At Engine restauration i have NOT changed the Valve springs. They was in the service limit; Could bad valve springs lead to that issue??

At least, Plugs looks for me nice white to minimum grey;
Exhaust is Delkevic 4 in 1 with Cheap Silencer from Louis (Megaphone Style);

Any suggestions from your side? Did i miss anything?
Should i give the Dyna S Ignition a try?
For me is even crazy why i need 2 shims on the needle. But as mentioned, she is running great to 7/8 throttle...

Should i perform with new B8ES or B9 Plugs a WOT Plug Chop - even with jerking WOT performance? Seems for me that this makes no sense?
Possiblity for arround 1.5km of WOT on public road...

Thanks in advance for ANY suggestion/help!
Cheers
Chris






 

Pulling stronger at wot when you close the throttle slightly means you are too rich .
No difference or worse when applying choke ( enrichener) backs this up
Pilot jet and needle should be returned to stock with stock needle position.
Main jet should only need increasing around 3 sizes from stock with the 700cc.
Use non resistor plugs.

Thanks;
 So I really should go back to 15 pilot, needle to middle stock groove, 107 main and see what happens?

But my plugs looks very nice and I have tested stock setting before some time. Big hesitation at start and bad acceleration…?

B8 or B9 without R is non resistor. But using resistor cable from dyna with graphite cores should be ok?
What do you think about ignition? Not possible that this is the problem?

If you use resistor plugs and resistor leads/caps you will cause a weak spark and poor detonation. The poor detonation will become more evident as the revs increase and the available burn time between cycles reduces.
There is no reason to have ANY resistance in the circuit. It was only incorporated originally to stop interference with analogue tv/radio signals. 
Whenever possible I don't run any resistance in the leads, caps or plugs. 

www.dynaonline.com/dyna-suppression-core...es-7mm-black-dw-600/

 This are the wires which I use. Think no resistor included; Please doublecheck.

 And as mentioned tested today NGK B7ES with no resistor. Maybe smoother operation but WOT same problem. Think Change to B8ES or B9ES will make no difference. But will test it next days and report. 

Thanks 

Womtong wrote:

Thanks;
 So I really should go back to 15 pilot, needle to middle stock groove, 107 main and see what happens?

But my plugs looks very nice and I have tested stock setting before some time. Big hesitation at start and bad acceleration…?

B8 or B9 without R is non resistor. But using resistor cable from dyna with graphite cores should be ok?



 

With the air correctors you must leave the pilots and needle position stock otherwise you will be too rich off idle and midrange which will cause bogging and this will of course stack up against the main to over richen the top end..
Both lean and rich conditions will produce similar symptoms for different reasons so you need to perform high speed plug chops to determine the mixture at high rpms instead of guessing.
700cc is within stock rebore sizes so the main doesn't need a dramatic increase.
Resistor leads are ok but don't use resistor plugs.

Thanks again.
 Cannot imagine that it will work but give stock setup a try.
 Needle 3rd groove, 15 pilot and 102,5 main.
 Plugs without resistor B7ES
 Will report.

Womtong wrote:

Thanks again.
 Cannot imagine that it will work but give stock setup a try.
 Needle 3rd groove, 15 pilot and 102,5 main.
 Plugs without resistor B7ES
 Will report.

You need to increase the mains from stock.
107.5  should be about right.

Thanks, will do.
Recommendation regarding plugs? 7, 8 or 9?

Womtong wrote:

Thanks, will do.
Recommendation regarding plugs? 7, 8 or 9?

Use stock plugs or possibly one grade colder if that 700cc kit is higher compression and your needle should be on the fourth groove from the top NOT middle. 
So one groove richer from the middle is stock.
 

Thanks; Will take 4th on needle and B9ES plugs. Keep updated

From your previous threads and posts your engine appears stock apart from the 700cc pistons and K&Ns.
Your WOT problem indicates that the full throttle mixture is too rich..
You should need no more than stock setting carbs with air correctors and main jet increase of around three sizes to 107.5 / 110 .
If that doesn't work i suspect that either the carbs have some incorrect internals from the parts swap or that the issue lies elsewhere.