77 KZ650B Restoration/Build

The 650 and 1000 use the same carb fuel Tee, which measures 8.3mm across the bulges. 7mm fuel line should work but something slightly smaller would be fine as well. What I don't know is about the petcock nipple...

Huh. When I looked on bike bandit and Kawasaki's site I see the 78 650 Tee as 92005-1010 and the 78 1000 Tee as 16046-002, but it's probably messed up because it shows two tee's for the 1000. Does the 1000 use two fuel lines?

One of the lines for the 1000 listed shows the same diameter as the larger of the two 650 lines listed. So maybe the 650 used a smaller line in 1977, but in 1978 it used the same as the 1000? There is so much missing info on the new Kawasaki fiches.

I couldn't find a Tee part number for 1977 650 on either site's fiche. Maybe just a plain google search for a part in a bag would yield a result.

I'd really like to pare down my fuel line stock to two simple sources/sizes. I have a giant box full of nothing but hoses and clamps and I'd like to toss the whole thing as most of it is annoying to use.

BTW, the yellow semi-transparent F-4040-A Tygon fuel hose seems to hold up to ethanol-gasoline pretty well, but it's really soft and flexible. The main problem is on hot days it likes to kink very easily. Plus I find it unattractive on the bike. Also it needs clamps to hold tight to the pipes but the clamps have to be very well-shaped otherwise the hose will seep. So bottom line is, it's not as good as factory, that's for sure.

From Partzilla for the 1977 650B... www.partzilla.com/product/kawasaki/92005...9204e6d0d453737fdbeb

I worry about the cross reference useage. Even Kawasaki used to list parts for bikes where they were not used. It was a software glitch where a part was considered to be used on a bike even though there was a note saying the parts was for a later model.

The few 1977 Kz650's I worked on definitely used smaller fuel lines than the 550.

The original 1977 KZ650 fuel line was 6.5mm ID and 11.5mm OD. I don't know if that size is still made by any fuel hose provider. Ed

Then I wonder what that 5.8 x 10.5 fuel line was for on the 79 parts fiche. I doubt they went to a smaller line in 78 and 79 after using a larger line in 77.

Going to go with 5/16 hose and see how that goes. I'll adjust sizes if need be but for now I'm gonna grab that size. Getting a regular in-line filter for now while I order these:

fortnine.ca/en/pingel-in-line-fuel-filte...ish-fuel-filter-ss1p

Unfortunately can't get the Golan Super Mini fuel filter here, they don't even ship to Canada. Any thoughts on the above? It's not as good as the Golan, the element filters to 40 micron unlike the 10 from Golan. But should surely be much better than regular disposable cheap ones

Also looking to replace the pod filters with new ones. They're stained with the gas leak and they are non-branded so I'm not really sure of their effectiveness or quality. I know most people advise against the pods, but I got them with the bike so can't do much now haha.

Seems like it's hard to find the 39mm sizing. One product claimed to work for 38, 39, and 40mm. Does this work? Can I buy a 38/40 mm filter and just tighten the clamp and it should still perform well?

What brands of pod filters do you guys recommend. K&N and Emgo are the only two I really see for 39 mm. Thoughts?

Finally cleaned the last carb, going to reassemble them this week. Will also check the valve clearances this week. Then, hopefully I can start her up this weekend

I use the 39 emgo pods on my 550 and they work great. No mess, very inexpensive. They jet about the same as k&n and uni, but don't require all the chemicals. I've used them for about 15 years. Before that I used k&n and uni's... did not like them.

Really frustrated with myself today. I had everything ready to finish up today, went out last minute to grab replacement vacuum lines as well. I mounted the carbs on the bracket and 2/4 carbs bolted to the rod. On the third one, the bolt didn't seat for some reason so I slowly turned for a bit until finally the bolt snapped. Part of it was sticking out so I couldn't slide the rod back out.

Frustrated... I guess I'm going to have to drill out the bolt and buy a replacement rod now. Ugh.

I lucked out and was able to find a full set of replacement carbs clean and ready to go from someone locally. I guess it worked out for the best, now I have a back up set of parts

Gonna get the rod swapped over. Also all the screws on my carb are pretty soft and starting to lose too much tread. Going to grab some replacement ones from the hardware store.

Hey, might be a silly question but would you guys rather get the bike started on potentially 2 year old oil to get it warm and easy to change? Or would you change it cold and maybe do another oil change in a closer interval to really get all the old stuff out?

I would drain the oil cold and remove the oil pan. Give the oil pump filter screen and oil pan a good clean.