77 # 39; Kawasaki KZ1000 cafe racer
Have you noticed how it can be to have a bike more idle smoothly, especially when the engine is cold your KZ idle speed too low cold engine and after idling the bike turns slowed too quickly when it is warm.
My KZ had these problems, even after installing new pistons and rings, valves removed and changed the joints, cleaning the combustion chambers, new ignition coils and clean Carbohydrates intake manifolds are newer, having been replaced in the last two years, what else could it be causing the problem.
There are many things to do and they might not be easy for a novice systematically with these tasks and the likelihood of success is high.
1 Clean carburetors The pilot jet system has small orifices which easily clog dirty fuel A former gas reservoir could have internal rusting Rust can enter the carburettors and the pilot block system.
Use this chart as a guide for Mikuni cleaning.
In the graph, the air flow is from left to right the passage of air pilot 2 and pilot stream 4 tend to be erased when a motorcycle sat for months with gas in carbs ethanol gas is worse than the old gas non-ethanol ethanol gas fouls carbohydrates faster than carb own non-ethanol use generously - that is, use as much as you need to get these holes and squeaky clean jets If you do not you might take carbohydrates apart soon and carburettor four cylinder banks aren t as easy to remove a bike.
2 Check for leaks intake manifolds If collectors seem to be as old as the bicycle, the change they could be 30-40 years and all it takes is a couple of cracks to cause air leakage and they screw up the engine to idle.
3 s Air Filter If you are running the original air box, a look at the air filter and decide whether it should be replaced if the filter is a UNI KN or replacement, it can be cleaned, oiled and reused.
If the filters are individual pod-type inspect each to be sure they're in good shape if they are not cheapies KINGDOM KN or take a look at the rubber clamp to see that it's not blocking the passage air pilot 2 in the chart above If air flow is blocked or clogged, could be the possible setting.
4 valve clearance If insufficient clearance, the valves do not close completely when they should and fuel mixture leakage through the valves while the piston is compressing the mixture before ignition It causes bad combustion and performance.
The correct play is 05 to 10 millimeters here is a helpful chart.
At least you'll need a feeler gauge to measure the game If permissions are outside the norm, the next step is to remove the hold 1 in the chart and check its size Size is usually indicated on the underside of the If no action shim s, the wedge can be verified by a bracket If the game is smaller than it should be, you want a small wedge thinner If the game is too large, you want a larger wedge.
How to remove KZ900 hold s and KZ1000 s have the hold on the design of the bucket and the cams gift need t be removed Kawasaki a tool that depresses the bucket and allows you to remove the shim ago after market tools that are so cheaper, about 10 to do the job then there's the cheapest tool - a zip tie very thick, I'll write about it in the future.
5 Ignition Unscrew candles, put back caps and turn the starter and watch Don sparks touch t candles while you do it, unless you want a shock Does each cap has a visible spark Otherwise your wiring may need work or coils may be due for replacement.
Using a multimeter, check the voltage at the wiring to voltage coils must be at or near 12 volts If the voltage is significantly less there could be a short circuit or electrical wiring may be old .
One way to get more power to the coils is the mod coil Wired George is not as difficult as I did you'll get the power to the coil parts cost is minimal, maybe less than 10 if you get a good deal on the relay, fuse and wiring.
Ignition timing is important if the timing is bad, it will affect the performance is how the time of your KZ1000 with a timing light.
Another ignition problem that affects the idle is the ignition advancer advancer The two springs and they lose their tension with age and mileage springs in new Advancer state are not available for all I know.
slightly shortening each spring will take over that doesn t spark advance sooner than if it will help a slow erratic Details shortening the springs will be produced in the future.
Buy or borrow a compression gauge with a 14mm adapter that screws into the spark plug hole of KZ1000 Before taking measurements, warm up the engine take the bike for a ride warm the Unscrew correctly all the candles, put the caps back on each plug then install the cylinder on compression gauge 1 Open the throttle fully and press the start button and watch the gauge When the psi compression reaches its peak on the gauge, release the start button and record the compression for that cylinder Repeat for cylinders 2, 3 and 4.
Good compression must be between 150-190 psi All cylinders must have a similar compression in about 15 psi If the compression is less than 150 psi but all cylinders are running the same pressure, it is okay unless the pressure is very low, as less than 100 psi.
I've done all the steps above and my KZ still had not slowed down the way I wanted for my next step I removed carbs and started to re-inspect the intake boots, even if they weren t that I looked more closely at the first intake manifold and the manifold bolts to the head were cowardly that can certainly cause a leak I removed the manifold, cleaned with a carburetor cleaner then reinstalled, ensuring that the screws have been tightened so I checked the other three collectors, they were all safe.
I started the bike and immediately installed in a stable idle No need to adjust the idle and when the engine has warmed my KZ functioned almost as good as new.
Lesson - check everything is normal to check things easier at first, but if you haven t solved the problem you will need to check things more difficult.
Andrews cams are no longer produced for Kawasaki KZ900 s s s and KZ1000 but they are still there and are on sale now and here are the specifications.
This is for KZ900 and KZ1000 s specifications for KZ650 KZ750 s and s are different.
Delkevic built stainless steel exhaust systems and they have added this silent style directly to their catalog Rated to 325 cooler, a good deal Moto GPWerks sells Yoshimura style stainless steel pipes Stainless steel 500 cooler than j 'have one on my KZ900 and Sá great system Webbike Japan has a wide variety of mufflers for KZ s Some of them, mild steel systems were evaluated in the 300-400 go awhile back now, these prices are rising stainless prices and titanium system become quite expensive, the cost of systems ti some of us to pay for a used KZ1000.
Delkevic's been selling this megaphone system for a while it s great price, but that doesn t cut mouthpiece for some of us.
Welding right around the center of just megaphone doesn t look right to many of us who are used to Kerker and Vance and Hines pipes Kerker yet exhausts for classic motorcycles, but prices rose much - now about 800 for systems Vance and Hines painted in black chrome are more affordable, but there have been complaints about the quality of their systems.
Delkevic pipes can be purchased Z1Enterprises and on e-bay.
I just finished upgrading my KZ900 with cylinders spare set bored out to 1015cc We used stock KZ1000 70mm bore piston with new piston rings and Webcam 118 camshafts The bike was good but didn t have the kick I expected.
Fortunately, I had a set of Mikuni smoothbores cased I gave them a clean and installed on the bike Today, I went to horse and what a difference when you look at a throat of a smoothbore and compare it with a VM26, it is much more I would describe as a worn carburetor.
Mounted on the bike, smoothbores like VM26 of the easiest difference to note is the large nut at the bottom of the float bowl on the smoothbore that allows changing the main jets without removing the bowls.
This set of smoothbores is projected with 17 120 5 pilot and main jet pilots could be a little on the small size, but they seem to work the air screw is about 1 8 to turn - using jets recommendations Wired George as a starting point.
smoothbores Mikuni were the high-performance carbohydrates for the Japanese four cylinder motorcycle in the 1970's and 1980's there still a lot of carbohydrates smoothbore in existence and they're getting pricey - count on a good sales job to play 500 minimum There are other choices these days Keihin CR Promotions getting a lot of attention, they are few and sell about 1000 Mikuni RS34 s are also popular and more affordable 700 or more.
Parts smoothbores Mikuni are still available - visit website Z1 businesses.
If you are looking to bolt on performance for your KZ900 or KZ1000, get a set of smoothbores, Keihin CR Promotions or Mikuni RS34 s.
There are a lot of inquiries about specifications for KZ1000 s here they are.
Oil-type front fork 10 weight many drivers suggest using 15 weight.
Tubeless tires are the norm, inner tubes must still be used.
Rear tire April 00 x 18 or 90 x 18 or 110 x 120 80 18 metric.
chain drive, 630 worm 92 with the links, the front sprockets 15, 42 back.
oil capacity 300cc front fork with prongs or 110 mm from the top of the oil level range with completely dry compressed filling forks 327cc by forks.
type front fork oil 10W20 weight many drivers suggest using 15 weight.
Front tire - tubeless 3 25 x 19 or 90 x 19 100 metric.
Rear tire - tubeless 4 25 x 18 or 80 x 18 120 metric.
chain drive - 630 with endless links 92, the pinions 15, rear 41.
Note - many other KZ1000 s and s KZ900 KZ900 have similar specifications to the specifications will be very similar to the KZ1000-A-1, other than moving and KZ900A a brake rear drum.
The KZ1000J specifications are similar to those of KZ1000C.
The KZ1000-K1 and KZ1000-M1 are similar to the J exception of a few things such as the size of rear tires 16 inches on the size of the gear K1 and M1 and rear, which is 39 teeth on the K1 and M1.
Put my KZ900 back together, the workshop manual is great but getting the right cam can still be difficult here for.
The distribution chain connects the crankshaft and you can not see if the chain and crank properly connect the crank can be turned clockwise with a 17mm wrench and the other hand holds the string to check Then you must maintain chain tension as exhaust cam is installed.
Once the exhaust cam is installed, the intake cam is installed and the chain are numbered 28 to ensure that the two cams are properly synchronized with each other at this point, the cam caps are not tight and cams float several millimeters above the point where they will be when the plugs are tightened the small arrow on the front of the camshaft exhaust should be at the cylinder head platform once the cam caps are tight If the arrow is above this level, it is likely the cam is timed tooth is about 12 degrees delayed the timing right Your bike will work well with the weather so far.
To correct the calendar, the four cam caps have come off, the exhaust cam must be positioned correctly, then count 28 teeth after the arrow and the time the intake cam torque again carefully the cam caps up Next add the guide wheel of the chain on the top, between the two cams be very careful to drop the parts in the engine If you drop a bolt or another piece of hard metal, it must be recovered before pull the engine.
With the two cams and the guide pinion of the cam chain attached, rotate clockwise crank using the 17mm key to the crank The crank rotates relatively easily Moreover, it is much easier if the candles are so well the crank rotates, continue turning 360 degrees and recheck cam synchronization has the crank, the synchronization mark is a small t to the left of the mark 1-4.
If the crank doesn t turn with reasonable effort, STOP Something is caught A likely candidate is the cam chain, having slipped teeth on the crankshaft Back to square one, remove the cam guide sprocket cam caps and cams, and repeat another problem I had - at one point, after removing the replacement cams, a cam bearings fell into place cams bolted without difficulty, but when I tried to crank it wouldn t go I removed the cams and saw that the landing had been destroyed by being clamped down position Luckily for me, I had an additional cam on hand.
This scheme is the workshop I highlighted in yellow some important elements manual The arrow on the exhaust cam must be at the platform of the Fit head of a link of the arrow, which is the first link and the link count 28 links 28 should coincide with a mark on the intake cam sprocket If it doesn t match, carefully remove the intake cam and the link correspond to the sprocket brand While you do this, keep the chain taut cam on the input side, if the distribution chain may slip teeth on the crankshaft the timing mark is at the crankshaft 6 in the diagram.
Also note, once the guide sprocket chain that roll between the two camshafts at the top is in place, it is difficult to count the links in the chain that I have tried and abandoned, it is much safer to count them first, then put the gears chain guide If you forgot to count, take the guide sprocket off the system and check that it is better to find the timing was not by folding a valve.
Once you have the cams correctly timed with the crankshaft, think about what an intelligent person you are for doing this correctly.
To remove your intake and exhaust valves, you will need a valve spring compressor The Kawasaki-made tool is expensive There are a few cheap tools sold online and in auto parts stores I went to O Reilly s and they have a great program where you can buy a tool, use it for 48 hours and then return for a full refund better than renting they carry a valve spring compressor and unfortunately it has not adapted KZ900 in my head I took it home and tried, not like this work.
Next stop, City Mill Kaimuki for an 8-inch C Clamp Note - this is not an original idea, I saw on.
Here's the clip I bought a pony clamp tool because I think he has done in the US It is a quality clamp and another necklace made in China was just a little money and less didn t look so well built.
The clamp has wooden spoons glued on the fixed side below, it is a small piece of hose was cut s.
Here's a closeup of the pipe This is a inch pipe that's been laying in my yard for years if it sounds familiar, I used another piece of pipe to make a tool of suppression KZ900 fork damper.
The use of an angle grinder, I cut about 3 inches long hose and a 2-inch side window I pressed the slightly closed pipe using locking pliers to tighten the window.
Here s actuation clamp the fixed part with wooden spoons glued on is in the combustion chamber when the exhaust valve is in this section of the illustrated clamp pushes the downpipe Rotate the clamp, keeping centered on the valve spring retainer and finally, guards the two pieces sandwiched between the retainer and the valve stem then fall pick up with a needle nose pliers or a magnet When the two guards are removed by loosening the necklace and then remove the springs can be removed oil seal is lower above the valve seat I pulled the old seals using needle nose pliers then pushed the new seals place using the valve stem as a guide.
cost pony pinch tools 20 The pipe was free and I had an angle grinder If you can not find a piece of pipe laying around, perhaps an old decision that you do not need will do some guys use plastic pipes instead of steel I'd be concerned about breaking the plastic pipe, which just my guess.
With these old bikes all poor electrical connection can cause havoc and give headaches a homeowner Two causes of blown fuses on KZ900 relative to the braking system.
The most frequent case is frayed wiring When you're riding around, the son throughout the bike moves a lot like you accelerate, brake and turn the handlebars After decades and miles of riding and coating plastic on the son can wear I was a case of the fifth wheel shorting rear brake, causing the brake light operates intermittently this short harness connects to the main wiring harness under the seat, and then moves to through a tunnel in the rear fender and ending at the tail light wiring tunnel had frayed and shorted periodically several times I disconnected the wiring, cleaning the contacts, reconnected the son and went on another tour later blew a fuse, went home and tried again Finally I pulled the wiring out of the wing and found the melee I could have used electrical tape to c Open the bare wire but replace the beam doesn t cost much and can prevent future frustration.
Sells this harness for about 15 This is a good price for peace of mind.
Here's an unusual cause a fuse to blow - the brake light switch before one had me stumped for a while when someone suggested it might be the problem I was skeptical Similar to the beam of the problem wiring, the short brake switch was intermittent.
This partial son in the tree threefold lower it its universal part located at the auto parts store fitting NAPA part SL134 costs about 15 motorcycles Kawasaki addition, the brake light switch is located on the old jeeps and other four-wheeled vehicles Unscrew the old passage of the triple tree and a cloth ready to catch the brake fluid dripping Insert the new switch, reconnect both son and bleed the brakes before resolved fuse problem.
Instructions for installing Dyna coils on KZ1000 s and four-cylinder motorcycles are lower than the 1973-1978 Z1 and KZ900 KZ1000 of using coils 3 Ohm Dyna green coils operate with electronic ignitions aftermarket dyna and also work with SKUs if ballast resistors are installed.
The Dyna coils installation can be a pain that I install on my KZ900 and used words repeatedly colorful as I worked to position them on the original mounting brackets with spacers and cable routing for to other bikes, KZ650 s example, many owners use L hooks, hooks of the original frame brackets and then using the corner of the other side to mount the coils.
The good news in my case was that the coils worked right away is very narrow routing cables that operate the reels then the spark plug son.
When cutting candle son if anything cut longer than necessary because you can reduce the later if you cut too short wire at the beginning, you may have to buy another set of son or whether this short wire run on another spark plug and son outside switch.
I like the aluminum handlebar because they rust t life in Hawaii the environment is wet and when you are near the beach of salt in the air on your bike rust and corrosion attack quickly, maybe why he aren ta lot of old classic bikes on Oahu.
Superbike bar chromed steel look great and cost more t donation a year or two later, the bars can start showing rust that I switched on a dirt bike handlebars aluminum for many of my road bikes .
An engaged to the aluminum handlebar on a KZ1000 is the flashing could suddenly run The cause - the handlebar should ground the chassis of the motorcycle aluminum handlebar are covered to prevent corrosion and coating can block electrical conduction.
The solution - use glass 300 or 400 grit paper works very well, and make the bar where it is located in the riser and also clean the paint on the riser.
Above you can see aluminum handlebar in the triple coating clamp on the handlebar should be scratched and it helps to scratch the paint tee where he is at the helm.
No need to go crazy with the sanding just enough to get a good ground connection between the bar and the clamp.
Then bolt the top clamps on, install the handlebar controls, handles etc and you should be ready to go If those aren parts t sanded the bike will probably work fine except the flashing may not work consistently or they may not work at all .
I like Renthal bars and buy usually used Make sure your bent bars aren t For vintage bicycles as KZ1000 you'll probably need a 7 to 8 inches in diameter Be careful when shopping for bar handlebar, because a lot of dirt bike racks are 1 inch and 1 1 8-inch diameter.
Dirt Bike racks are often wider than the bars in the streets Sometimes I cut an inch on each side for shorter and the cables and wiring fit nicely Pay attention to the cut because if the rods become too short the brake master cylinder may not tighten if it is where the handlebar elbows Cut a little at a time until you are satisfied with the width of the bar and everything goes.
information KZ1000 Kawasaki, Kawasaki, KZ1000, the chain guide sprocket, the stop lamp switch.