Lost cover :(

Hi All,

I have a 81, kz1100. I noticed that the #2 cylinder wasn't firing so I put my hand over the throat of the carb and it fired.

I removed the bank of carbs and cleaned out the #2. In doing so I applied some compressed air, and the little round metal cover in the float bowl shot out and is now lost.

Any idea where I can get another one or is there some way to fix this?

THanks

ggenovez wrote:

Hi All,

I have a 81, kz1100. I noticed that the #2 cylinder wasn't firing so I put my hand over the throat of the carb and it fired.

I removed the bank of carbs and cleaned out the #2. In doing so I applied some compressed air, and the little round metal cover in the float bowl shot out and is now lost.

Any idea where I can get another one or is there some way to fix this?

THanks

Question, please - - - Does the little round metal cover in the float bowl appear in this diagram (from Kawasaki.com)?

[Click on image to enlarge view]

The one circled in the pic below, right? That is the plug over the pilot jet (not to be confused with the plug over the pilot screw). Some BS 34s use metal plugs, some plastic.

The pilot jet plugs are used on the following Kawasakis (plus a lot of other bikes including some Suzukis and Yamahas).


KZ1000-J3 (1983)
KZ1000-K1 (LTD) (1981)
KZ1000-K2 (LTD) (1982)
KZ1000-M1 (CSR) (1981)
KZ1000-M2 (CSR) (1982)
KZ1000-P1 (Police 1000) (1982)
KZ1000-P15 (Police 1000) (1996)
KZ1000-P16 (Police 1000) (1997)
KZ1000-P17 (Police 1000) (1998)
KZ1000-P18 (Police 1000) (1999)
KZ1000-P19 (Police 1000) (2000)
KZ1000-P2 (Police 1000) (1983)
KZ1000-P20 (Police 1000) (2001)
KZ1000-P21 (Police 1000) (2002)
KZ1000-P22 (Police 1000) (2003)
KZ1000-P24 (Police 1000) (2005)
KZ1000-P3 (Police 1000) (1984)
KZ1000-P4 (Police 1000) (1985)
KZ1000-P5 (Police 1000) (1986)
KZ1000-P6 (Police 1000) (1987)
KZ1000-P7 (Police 1000) (1988)
KZ1000-P8 (Police 1000) (1989)
KZ1000-R1 (Eddie Lawson Replica) (1982)
KZ1100-A1 (Shaft) (1981)
KZ1100-A2 (Shaft) (1982)
KZ1100-A3 (Shaft) (1983)
KZ1100-D1 (Spectre) (1982)
KZ1100-D2 (Spectre) (1983)
KZ1100-L1 (LTD Shaft) (1983)
KZ650-H2 (CSR) (1982)
KZ650-H3 (CSR) (1983)
KZ750-R1 (GPz) (1982)

As you can see the Police models up to 2005 use the plugs so they should still be available .

The Kawasaki OEM part no. is 92066-1087 - BikeBandit carries them for $ 3.20 a piece, BikeBandits part no. is 630117-001.

Btw, wish I had your "luck" - all four plugs on my BS 34s are stuck solid so come winter I'll have the pleasure of drilling them out to find out what size pilots I have in there, seems like some po mashed them in there, maybe even upside down...

Thats it. Thank you,

BTW, any chance some PB blaster and 120 PSI can shake them loose? I applied air to the hole just before it and it shot out...

You're welcome, no problem.

Nah, tried that already, they wouldn't budge. They're completely stuck, a buddy suggested they might be in upside down or at least stuck too deep - they're sitting flush with the carb body so I can't even grab them with a pair of pliers. When riding season is over I'll drill them out and replace them with the plastic type plugs.

OnkelB - Keep in mind when you do this that there is a cast tab in the float bowl that puts pressure on the metal plug that fills the pilot well. You might try asking Jeff at Z1Enterprises.com to get you a set of Suzuki rubber plugs which are still available. I think they would work fine but have never tried them with a Kaw float bowl. They are solid rubber plugs that press fit in the hole and inexpensive. They are available through K&L Supply I believe and Jeff is one of their fine dealers.

The plug can be blown out IF you put your finger over the main air jet on the edge of the venturi and blow air into the main jet itself. there is a cross passageway between the pilot and main wells where gas gets across and to the pilot jet. This well MUST be plugged if the carburetors were originally designed with this cross-passageway.

I am not sure where new metal Kaw style plugs can be had. There is a dim possibility that they are still available from Kaw new as I THINK that they were used on the cop bike as late as 2005.

Thanks George, I'll try that before I drill. Any risk of damaging the diaphragms when blowing?

And I'll definitely try the rubber plugs, at least they shouldn't get stuck.

I don't know if it's an issue on teh BS. carbs. Have a look at the cuircuits to be sure. You can always pull the diaphragm to be safe.

The air inlet to the diaphragms is in the intake side venturi... the LARGE slot at the top. No air enters the venturi via the air jet except through the main jet and there isn't enough pressure to hurt the diaphragms. You could remove to be safe. The plug you are showing is installed upside down maybe but there is a small ridge in the well and it just shouldn't be that deep. I doubt you will remove it by blowing air but I would try that first. If it doesn't come out with air, drill and use an EZ out or other extraction tool that can grab it. Perhaps a left hand drill bit would spin it out... don't know as I have never seen this one before. A lot depends on the size and condition of the oring which can make that plug a bit sticky.

Ok, thanks for the input, I'll give it a shot come winter. The bike actually runs fine, just bugs me that I don't know the size of my pilots plus I hate when things get stuck.