1983 KZ1000R2 Project

Another day, another attempt.
Started her this morning, and she sound good at first.
But then the RPMs built up again and I shut her down.

youtube.com/shorts/LcIkKOw_mQg?si=G4No8fIcwVisrC3h

I walked around the corner to a neighbour who has had a few Kawasakis.
He came over to have a look, thinking we'll spray the carb holders looking for leaks.
We had her running long enough to reveal the issue.
Gas started pouring out of the air box!
He kept the engine under control by putting his hand over the air intake.



The carbs are flooding the air box and filling the crankcase.
The fuel levels must be too high.
So off come the carbs.
 

I had this carb stand set up for the KZ650 carbs.
Having some extra carb holders for these BS34 carbs, it's easy to set up the stand.

 
 

Add some gas, and as suspected, the fuel levels are high.

 
 

Adjust the tangs on the floats a little higher, and the fuel levels look better.

 

The test fire today didn't go any better.
The RPMs were high again, around 4000 RPMs.
Putting my hand over the air intake slowed her down.
Pulling the choke would make her die.



I pulled the carbs again, after checking the fuel levels while the carbs were on the bike.
3&4's levels were high.
Adjusted again, and reinstalled.
Test fire tomorrow.

 

I bought a chain guard and dash off Jay from California.
Unobtainable anywhere else.

   


My dash was broken around the mounts, and the bolts did not fit anymore.

 

 
 

I had sent the carbs off to a friend's, Steve.
He had a look at them.
I picked them up today at his place:

 

He said they looked good.
He got them to stop overflowing.
Using the spec measurement of 18.6mm, he set the float heights.
Basically bending the float tangs more, in the direction I was going.

He did say to me, make sure the butterflys are closing, that you hear them shut.
Sure enough, as I was installing the carbs, I checked the throttle return and the butterflys were not closing.

 
 

In my attempt to shorten the outter sheathing of the cable, I nicked the cable.

 

I do have the old cable.
It'll have to wait until tomorrow...
 

Everything hooked up again, using the old throttle cable.
She now idles!



Need to fine tune the idle, then sychronize the carbs,
Getting there.

youtube.com/shorts/Gltn8cR3jkc
 

Congrats Rob!

I know there is still more to do, but think about all you have done so far in a short amount of time. The bike looks great, and keeps sounding better and better. I look forward to your review of your Zrx vrs R1 comparison.

Still had some running issues, so off come the carbs again.
Going to have a look at the carb holders to cylinder head seal...

 
 

Seems they were not in the best of shape.
I had bought two new sets of carb holders, but the inside diameter was only 30mm on them, instead of 34mm.
My local dealer said he could have the holders enlarged.
Picked them up, and reinstalled them with sealant:

 
 
 

The Hindle exhaust that came with the bike did not look that great. 

 

I spotted a new Delkevic Stainless steel one for sale on Ebay for $399 US$, that I couldn't resist.
I have had the same style Delkevic on my 1978 KZ650 for over 10 years,
Great exhaust.

 
 
 

Will not miss these:

 



 

Each time I reinstall the carbs, the carb holder clamp bolts butt up to something.
Mainly the #3 carb clamp, comes awefully close to the throttle cable holder.
So I shortened each bolt a little.

 
 

Now some clearance to the throttle cable:

 

Carbs back in, tank on.
New Kawasaki petcock too.

 

All put back together, and test fire:





 
 


 

The battery has some issues.
I had to use a portable booster to start her each time.
The first time she kept running when I disconnected the booster.
Second time she died when a booster clamp popped off.

I have another new battery coming, different brand.

I bought a new battery.
Much stronger, and she starts well.
Idle was a bit high, but turning down the idle screw helped.
Still not running great, but getting there.
I changed the spark plugs to NGK B8ES from the Splitfire plugs that were in there.
Changed the oil & filter again. Exhaust not heeded to be removed.



I bought a stainless steel engine bolt kit, and replaced the left and right engine bolts, many of which were rusty.

I fired her up today.
She sounded good.

The weather is going to be great this week.
I think a test ride is in order.