Piston Hole Kz1000LTD 1982

I have not had a left hand control unit from a 82 1000 apart, but on many other years and size Kaw bikes from that time span, it is a simple switch. There is a metal clip that hits the handle bar when the button is pressed and creates ground.

Thank you all. I took the plunge and disassembled the switch, and is finally working. Lots of brake cleaner and some toothbrush action made the trick. All electrics are working finally....

And today, at last, carbs arrived from the US. It´s only been 4 months "trip". Really excited about the real possibility of getting her running at last!

On a final note... I am having a difficult time getting the airbox in, as the electric cables are on the way. The main loom cables coming from the front are thick... 

Will keep juggling them until everything fits.

Cheers!

C. 

Ok. Jim’s carbs finally arrived! It’s taken a while but well worth the wait.

I have disassembled them to clean them with ultrasound and everything in spotless now.

However, I’m a bit puzzled, as for each of the carbs I have a really tiny and thin washer that cannot find where it came out. Actually, I don’t remember getting it off anywhere, but it got loose with the cleaning. It’s really small, and cannot see it in the manual either. Here’s a couple of pics for reference. I’m adding an ebay kit pic, as I can’t get a really good pic.

Any ideas where this may go?

The needle in the pic is just for a size reference

Well… this is pretty big news for me. Today, after 20 years and 2 into the rebuild, the kz has started!

I feel thrilled and enthusiastic about it. I know there’s a lot of work to be done, but it’s a big step for me. 

Here’s a video of the moment, and some pictures of how it’s going.

thank you all. This would have not happened without your help, and Jim’s carbs! 















The video: 

 

Fantastic job Carlos, she looks great. I hope you are proud

Great to see you at this stage Carlos, one thing I would point out is that your airbox rubbers need to rotate slightly. The "cut out" should engage with the raised part on the airbox and this ensures the flat part between 1 & 2 and 3 & 4 are aligned and that the rubber engages with the carb correctly

Thank you wookie! I am totally over the top. Having a working engine, with good oil pressure on the first try is a very satisfactory situation. 

I am installing the exhausts now, which will allow me to test the engine without waking up next door neighbors, two streets away. 

Yes. I understood the little "dimple" in the intakes was to be aligned with the line in the air box, but my airbox is a bit skewed to the side, and I had to turn a couple of them a bit, so the funnels would fit right. 

Overall was not too bad to get the carbs in; but it all boils down to having new intake rubbers, which are exptremely pliable. Had it not been the case, it would have been a nightmare.

Despite what I just said, I´ll try to turn them and see if I can get them straight.

Cheers!

C.

The tiny washer belongs to the adjustable pilot air screw!
pilot air screw----> spring --> washer --> o-ring, put it on exactly in this order.....

 

I did try that, as I remembered from my kz carbs, but the washer did not fit in there and the needle is totally different. 

Big update today. Several things:

1.- Engine starts really badly, but once running (20 seconds later), runs really sweet, keeps a stable idle and revs up quite nicely. See video attached

2.- All gears work perfect! I was worried as I could not test all gears when it was disassembled, but now I am happy all gears go up and down perfectly 

3.- I wanted to, as always, get carbs in sync. However, when I connected the vacuometer (yes, I still keep a mercury vacuometer), I was surprised to see that cylinder 3 (reference) is very high, 1 was absent and 2 was very low. I’ve attached another video.
I’ve now gotten 1&2 to be at the same level, but they are extremely low on comparison with #3 and, whenever I try to raise them, I get knocking and the idle goes down and almost dies.
not even arrived at touching #4! 

Any ideas?