1978 KZ1000 Project

The main jet size number location is on top for the main jets.
The pilot jet size mumber is imprint on the lateral circumference and not on top!!!

The handlebar switches need to be notched to allow the wiring to escape when fitting to other handlebars.
The Kill switch was broken.
I was able to repair it using a spare.
Wrapped the wires when completed.

Hello rstnick,
There was something wrong with your last post which forced me to delete it. Would you please recreate it?
Thank you
Bill

Sorry about that Bill.
Probably me trying to attach a video.

Worked on the Gauge cluster's wiring.
The blue wire/circuit was broken, and once I finished repairing that, the Brown wire/cicuit did the same thing.

Wires soldered:

Shrink wrapped:

Then all taped up and rear gauge cover put on:

Can someone post a picture of under the seat?
On a 1978 KZ1000 or simialr.
I want to see how the air box sits etc.
I have a Service Manual, but did not find any under seat pictures.

I imagine the air filter can be changed easily?

Thanks.

Rob I don't want to be a smart ass but that joint on the blue is going to give you problems later. that looks like you melted the solder with the iron rather than heating the wire and melting the solder on  by laying it on the cable. If there is any "blackening" on the cable it will oxidise and not solder correctly. These sleeves from Amazon etc are a better option and cheap enough

Wookie58 wrote:

Rob I don't want to be a smart ass but that joint on the blue is going to give you problems later. that looks like you melted the solder with the iron rather than heating the wire and melting the solder on  by laying it on the cable. 

I did do a little of both; I first heated the wires only, then applied solder to the opposite side, and I could see the solder drawn across.
I then added more Solder, so that kind of got painted on.
I think it will be fine.
Otherwise it will need rodoing one day.

Thanks for the heads up and tips.

It is a rosin core solder, and seems to stick to the copper wiring well.
Other solder I have, and tried, doesn't seem to stick.

I hate putting together something someone else took apart.
The KZ1000 is similar, yet different than the KZ650 I know so well.

For instance, the air box fitting.
There are two posts on the bottom of the 1000's air box.
I assumed they lined up with the support that's already there, between the frame.
This support doesn't come close to the air box. Must be for the battery box?
The air box sits forward and about an inch below the support.

I tried looking at parts diagrams, but not seeing a support bracket for the bottom of the air box.
Nothing on the sides of the air box, like the 650's.
If someone can help me with how the bottom mounts up would be great.

If anyone can take some pictures (or I can try searching through some threads) of under the seat and side covers.


 

Is either part #18 or #20 the air box support?

Again some pictures would help routing some of the wires, as it was worked on before me.

My parts order came in from Z1E.

Changed the one broken Choke plunger spool:

Checked what Pilot jets were in the carbs: 15
Which is stock for the year.
I was suspecting other jets in the carbs because there were Pod air filters on her.
Gave them a bath and cleaned them out, as I couldn't see through them to start.

Had another go at removing the Points plate screws.
My Impact driver bit was worn out, but having sprayed the screws with some penetrating oil the day before, I managed with a bigger hammer and a screw driver to loosen the screws.
The larger screws holding the points housing to the engine I was able to use the Impact Driver with a larger bit.
Housing off, and gasket scraped.
Ready for reassembly.

Have figured out a little more of the puzzle.
Seems part #15 supports the airbox: