New KZ Rider

Hello,

Recently purchased a running 83 KZ550. A vid decoder tells me it's the "C" trim. The bike was a cafe build that wasn't finished so I'm trying to get it in the best running shape without spending a fortune. Here's what I know (I'm a gear head but not smart on bikes, especially older ones so don't hold back lol).

The control cables are not routed correctly and the gas tank isn't secured and was basically wedged over the cables and wiring harness to hold it on. This made a kink in the throttle cables and caused them to bind a little and after closer inspection they seemed to be too long. This made controlling the throttle a little sporty and I've since ordered new ones.

The PO installed Air Filter Pods that don't fit (too large) and are just smashed on. I've looked around for the stock air box but it seems these are either hard to find or that the tubes are usually damaged. I don't have any of the mounting hardware either so I'd like to get correctly sized pod filters and rejet the carbs. I know there are issues with strong winds but I'm honestly no too worried about it, I'd just like to have it run correctly. I've looked at the Z1 website and figured I should probably just get the carb rebuild kit and a jet kit. Would someone help me determine which of the two links below would be best for this? The second kit seems to be the best for me since it's a rebuild kit and has multiple need sets. (The PO also installed an aftermarket exhaust that goes 4 into one, more on that next).

www.z1enterprises.com/dynojet-carb-kit-gpz-550-1982-83.html

www.z1enterprises.com/keyster-premium-ne...50-C4+550+LTD%2F1983

The Exhaust is a aftermarket 4 into one. The far right side (when sitting on the bike) has a pretty nasty leak and is making a decently loud slapping sound. The flanges are warped and the bolts/washers are pretty weak as well as the exhaust studs are bent a little, especially the one that has the leak. To address this I figured the following parts from Z1 might help:

Billet Exhaust Flanges
New Lock Washers
New Flange Nuts
New Copper Exhaust Gaskets
New 6mm x 27 mm Exhaust Studs

Other misc items...

It has a Renthal bar and the grips are literally zip tied on and are not locked in place (you can twist them both). I figured I could just get new grips, but I would like a new throttle tube assembly if they are easily sourced or if there are universal ones that are nice enough.

The rear brake light only works with the brake pedal, not the hand brake so I'll need to address that.

The rear brake is aftermarket and is a small LED strip, and the wiring needs cleaned up/fixed.

I have an oil change on the list, new plugs (super fouled due to the pods/improper jetting), cleaned/lubed the chain already...

Aside from cleaning years of oil/grease off the engine it sounds pretty good despite the issues and for the short 50 miles I took it out on before the throttle was stuck open, I really enjoyed the bike. I've since pulled it apart a little to make cleaning it easier and I'm looking forward to getting it back on the road in a week or two. Thanks for reading and I'm open to any advice or any better ideas on the parts above. I'll be searing through the forums to get better informed as I go.

Thanks

Welcome to the fold. Thanks for telling us your plans for your bike. We like pics. Lots of them. They can also show us the problem with your ride. Where are you?

Howdy. loudhvx has a motorcycle stuff page with tons of info for the KZ550. see links in his signature. you may have to be signed in for access to some of the links. Partzilla has diagrams w a cross-reference. find your motorcycle, choose a diagram, then click a part for the x-ref.

Hello and Welcome

Thanks for the welcomes!

azman857, I'm in the lower Alabama area. Thanks for the welcome! I'll load some pictures as well.
martin_csr, Thanks for the info, I'll be looking into his stuff for sure, I wish he could just rebuild my carbs for me!
Mikaw, Thanks for the welcome!

Pic upload

If you really want somebody to rebuild the carbs for you, give WG a call. Several members here have used his service and have been pleased with the results.

www.wgcarbs.com

Also, when posting pictures, if you click the Insert or Insert All button before posting, the pictures will show up full size in the post.

83KZ550 Wrote

"The Exhaust is a aftermarket 4 into one. The far right side (when sitting on the bike) has a pretty nasty leak and is making a decently loud slapping sound. The flanges are warped and the bolts/washers are pretty weak as well as the exhaust studs are bent a little, especially the one that has the leak. To address this I figured the following parts from Z1 might help:

Billet Exhaust Flanges
New Lock Washers
New Flange Nuts
New Copper Exhaust Gasketsß
New 6mm x 27 mm Exhaust Studs"


Regarding the exhaust please post a photo of the exhaust and problem flange.
Click Add Files and select your photo.
Place the cursor where you want the pic in your reply
Click the Insert Button directly below selected attachment.




The reason I ask is because the issue you describe is known with some MAC exhausts. I had one. On mine the flanges were relatively thin and soft and it took very little torque on the flange/stud nuts to bend the flange, distort the studs and cause an exhaust leak. I replaced the studs but found it impossible to straighten out the flanges as they are not removable from the header. Check my photo below before you spend money on flanges that may not fit if your system is a MAC.