Thought i was done

50 or so miles into breaking in my 80 ltd I have two problems, a crack in the tank seam and the one that sucks, at idle with clutch not touched i get a hell of a rattle, pull clutch in all is well no rattle. Pretty sure that points to a clutch basket issue.

Ive had the clutch rattle thing on a couple of bikes (Hondas) and its never been a problem. 'They all do that' is the reply.
Ive heard that balancing the carbs can go aways to calming it down.

Carbs are fresh, synch and all, stethoscope to clutch cover points to that area. Even pulled the clutch cover and inner hub, can wiggle the basket with my fingers. Definitely loosened up quite a bit.

Sounds like It's going back to the laundry room,
Pete

Hopefully it's not the rivets on the basket. They can be welded but splitting the cases are involved.
Steve

Yup, gonna go back in the house.

Good news though, fast, stops like crazy, starts easy, handles well. Got all the electrics working just somehow found a turd of a clutch basket. Tank is getting rinsed out, have an inch long hairline crack that needs brazed. I'm definitely keeping the Z1 bodywork on it.

If you're lucky the nut came loose.
Steve

Nope, first thing I checked. Should have went with my instinct and tracked down a J motor for this bike.

A few years ago wireman/plummen said a good upgrade was a shaft drive clutch hub assembly, I have one in a box somewhere. 6 spring setup, or I'll have to shell out the $200 or so for APE to do it, unless I can figure a repair out

Also need to nab a smaller tail light. Wanted to run an early style fender but don't have the room with the 18" rear and the zx6 swingarm

Done? Are they ever done?! A radiator shop may be able to braze that tank (unless you can?)

Noticed you have an h2 as well.....

I brazed it up ten minutes after I drained the gas, that's why I said it was no biggie. Took more time to find the torch and flux than it did to repair the crack

When it's back together and running it will be done, got too many bikes (and a house) to worry about before revisiting this kz again. I've affectionately called this one 'spare parts' cuz save for the frame, swingarm and tank that's all it has been

I thought mine would be done the other day, but currently the carbs are on my bench for a double check and to change pilot jets and fit different float bowls to eliminate the accelerator pump. I'm telling myself this will be the last time and after that she'll be ready to ride all next year when the weather warms without having to touch a wrench.

Bad luck with your problem, but 'I'd double check nothing has gone out on your carb balance or something like a float is playing up before throwing my hands up in despair. My KZ1000 wasn't running right when I bought it and the clutch rattle was truly awful. I know the old "they all do that sir" but it was much worse than that - rattle on steroids. I set the float heights and got everything running well and after a while realized the noise had miraculously gone away, I got so engrossed in every thing else I'd forgotten all about it, until I thought about it one day and then thought "what clutch rattle". I checked the carb synchronization and it was fine as it came, but with the wrong jets and one float level too high so it ran a bit rough at low rpm, it sounded horrendous, I quite expected attention would be needed there, in fact that was one of the reasons I beat the PO up so much on the sales price.

Why are you doing away with the pump?
Steve