81 KZ1000 G1 Throttle Switch Interchange TPS/ TVS

I'll Start as saying this is a compilation of two threads to get this interchange information;
1st is: kzrider.com/index.php?option=com_kunena&...mit=20&limitstart=20
2nd is: kzrider.com/index.php?option=com_kunena&...ew&catid=4&id=423679
Now this is the machine that is owned by member newOld_kz1000, beautiful bike!

Then the important info starts.
Kawasaki started using EFI on this model, and it is a one year design. When searching the part that was diagnosed to be suspect was No Longer Available/NLA from Kawasaki, #27004-1006
SWITCH ASSY,THROTTLE
So the search was on, and some of you may have been there done that, but a exact match was found.

This was, 1986 Nissan 300ZX Turbo "Throttle Position Sensor", the part is mfg. by 'Nile', #W0133-1708015 also crosses to Beck/ Arnely #158-0492. Now he went to Auto Zone and bought their #EC1060 BWD brand.

This is from newOld_kz1000 going to the Car wrecking yard and searching for a match, then looking for a new part to purchase.

So Kawasaki #27004-1006 = BWD #EC1060 or Beck/ Arnely #158-0492, Also Nile #W0133-1708015.
Don't give up hope for finding parts for your 1 year Kawasaki!!!!!!
Now I'll add a few Links for some back ground to this system that is used on the KZ Z1 Classic. First it is a L-Jetronic Bosch system that was used for many years in the Automotive world, and many parts are not used in the Kawaski system that would be on a car, but the ones that they share are similar or exactly the same. Don't expect to get a computer this way, or the wiring harness, but possibly any of the other Fuel system components, like the resistor block, Injectors, Double relay, pressure regulator, etc.
Here are some links on the system:
Put this whole line into your browser search bar:
bama.ua.edu/~darren/boschindex.html
This from Bosch, their tech manual.
Then:www.hiperformancestore.com/Ljetronic.htm
This has some good trouble shooting, including testing the Throttle Valve Switch.
This is the wiring diagram for the model, here on KZR under file base, which you need to register as a member to get into.
kzrider.com/mambots/content/multithumb/t...20da615eb49ed63b.gif

So here is member newOld_kz1000's list of things he had checked out to get to this point,

So far I've done this:

- valve clearance check -- they are fine
- new spark plugs
- electronic ignition pickups -- fine
- new oil and filter
- fuel pump turns on -- yes (still need to check fuel pressure)
- new fuses
- check coils -- they are fine
- check Run/Stop switch -- fine
- check battery and charging circuit -- fine
- disconnect and clean contacts of connectors and wires -- done
- remove computer, clean contacts, reinstall -- done
- temperature sensor -- is fine
- air flow switch -- 1/2 done, fine so far
- found and fixed major kink in gas line from gas tank
- removed and cleaned fuel petcock

On my list of things still to check:
- fuel pressure
- finish air flow switch check
- check the fuel injector's relay
- check ignitor's ground
- check the ignition switch
- find wire to secure injectors
Please note: Although no board code and smiley buttons are shown, they are still usable.

Hopefully his Info will help keep these machines going, it is hard when parts are NLA, and getting someone these days to work on a system such as this might be harder than the parts availability!! :laugh:

On my 1982 GPz1100 B2(the third generation FI I believe) at idle the fuel pressure is 33 PSI going up to 35 PSI as soon as the throttle is opened.

Your tank probably has a one way valve for fuel return,if it becomes clogged the system will run rich, making you look again in non obvious places for the fix.

The website www.750turbo.com has alot of FI tuning tips that might help you.

For your high pressure fuel lines(33 PSI +) make sure to use the rated stuff, also do not use the standard "Worm Style" clamp as the rubber will extrude through the clamp ruining the hose(possible fire hazard).

Pep Boys and other auto parts suppliers have special FI hose clamps that should be used.

MFolks wrote:

For your high pressure fuel lines(33 PSI +) make sure to use the rated stuff, also do not use the standard "Worm Style" clamp as the rubber will extrude through the clamp ruining the hose(possible fire hazard).

Pep Boys and other auto parts suppliers have special FI hose clamps that should be used.

Kawasaki : KZ1000-G1 Classic (1980)


Tag Description Req Price
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SKU: 11009-1182
GASKET,RELIEF VLV FIT 1 $2.55 Add to Cart
2 SKU: 11034-1723
BKT,PRESSURE REGULATO 1 $13.31 Add to Cart
3 SKU: 120P0508A
BOLT,SOCKET,5X8 2 $2.37 Add to Cart
4 SKU: 13159-1006
CONNECTOR,FUEL PUMP 1 $6.86 Add to Cart
5 SKU: 16130-1002
VALVE ASSY,RELIEF 1 $29.94 Add to Cart
6 SKU: 16162-1002
REGULATOR-FUEL 1 $99.14 Add to Cart
7 View Sku Supersession
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SKU: 220B0620
SCREW PAN HEAD 6X20 2 $2.55 Add to Cart
8 View Sku Supersession
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SKU: 220B0620
SCREW PAN HEAD 6X20 4 $2.55 Add to Cart
9 View Sku Supersession
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SKU: 461F0600
WASHER SPRING 6MM 4 $0.99 Add to Cart
10 SKU: 31064-1002
PIPE ASSY 1 $45.81 Add to Cart
11 SKU: 11034-1721
BKT,FUEL PUMP FITTING 1 $12.08 Add to Cart
12 SKU: 11034-1722
BKT,FUEL PUMP FITTING 1 $35.01 Add to Cart
13 View Sku Supersession
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SKU: 410B0500
WASHER PLAIN 5MM 2 $0.99 Add to Cart
14 SKU: 26011-1076
WIRE,FUEL PUMP LEAD 1 $24.78 Add to Cart
15 SKU: 49019-1001
FILTER,FUEL 1 $13.28 Add to Cart
16 SKU: 49040-1001
PUMP ASSY,FUEL 1 $442.43 Add to Cart
17 SKU: 92015-1101
NUT,12M/M 1 $2.52 Add to Cart
18 SKU: 92027-194
COLLAR 4 $2.79 Add to Cart
19 SKU: 92037-1178
CLAMP 5 $3.63 Add to Cart
20 SKU: 92037-1181
CLAMP 6 $2.29 Add to Cart
21 SKU: 92037-1206
CLAMP 1 $1.07 Add to Cart
22 SKU: 92059-1120
TUBE 1 $9.42 Add to Cart
23 View Sku Supersession
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SKU: 92059-1121
TUBE,7.5X13.5X272 1 $45.11 Add to Cart
23 View Sku Supersession
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SKU: 92059-1121
TUBE,7.5X13.5X272 1 $45.11 Add to Cart
24 SKU: 92059-1122
TUBE,7.5X13.5X285 1 $89.34 Add to Cart
25 SKU: 92059-1134
TUBE 1 $77.40 Add to Cart
26 SKU: 92059-1146
TUBE,7.6X14X140 1 $14.95 Add to Cart
27 SKU: 92059-1147
TUBE,7.6X14X360 1 $14.98 Add to Cart
28 SKU: 92075-277
DAMPER RUBBER 4 $1.26 Add to Cart

Tag Description Req Price
1 SKU: 21175-1001
CONTROL UNIT,ELECTRO 1 $1,365.70 Add to Cart
2 SKU: 21176-1001
SENSOR,TEMPERATURE 1 $85.33 Add to Cart
3 View Sku Supersession
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SKU: 220B0408
SCREW PAN HEAD 4X8 2 $0.99 Add to Cart
4 SKU: 461F0400
WASHER SPRING 4MM 2 $0.99 Add to Cart
5 SKU: 27002-1007
RELAY ASSY 1 $88.52 Add to Cart
6 SKU: 27004-1006
SWITCH ASSY,THROTTLE 1 $66.47 Add to Cart
7 SKU: 28011-1009
METER,AIR FLOW 1 $501.96 Add to Cart
8 SKU: 120P0540A
BOLT,SOCKET,5X40 8 $3.04 Add to Cart
9 SKU: 13091-1076
HOLDER,FUEL INJECTOR 4 $10.72 Add to Cart
10 SKU: 13169-1434
PLATE,FUEL INJECTOR,B 4 $4.08 Add to Cart
11 SKU: 49033-1001
INJECTOR,FUEL 4 $249.81 Add to Cart
12 SKU: 92027-1259
COLLAR,FUEL INJECTOR 8 $1.75 Add to Cart
13 SKU: 92055-1082
INSULATOR,FUEL INJECT 4 $7.78 Add to Cart
14 SKU: 92075-1240
INSULATOR,FUEL INJECT 4 $4.02 Add to Cart

I believe the "G" model along with the 1981 GPz1100 B1 shared the air flow sensor. One thing Kwasaki did on the 1982 GPz1100 B2 model was better insulate the fuel injectors from the engine heat with different intake configuration. If not, the injectors may have a shortened life....

On the 1981 GPz1100 B1 and the 1982 GPz1100 B2 the Throttle POsition Sensor(TPS) was moved to the right side of the engine mounted on the throttle shaft. It's a carbon based variable resistor that needs periodic cleaning.

On my bike, with the engine off, I carefully remove the SS clip securing the electrical cable to the sensor, and then with the cable out of the way,I spray some "De-Oxit" electrical contact cleaner/preservative up inside while opening and closing the throttle several times.

I use the "Dust Off" spray to remove and residue and dry inside the sensor. Reconnect the cable and clip and it should be good for many years.