Need some quick help with 81 kz1000 carbs.

I have cleaned and replaced rebuilt my cards today, but ran into a problem. I can't remove the cap for my pilot jet, with the way the main jets were clogged i can guarentee that this sucker is too. Is this the right cap. Sorry this is my first time ever rebuilding a set of carbs.

WOW, i'm surprised someone didnt jump on this sooner... :huh:

YES, that is the correct cap, and it is actually a few mm long, as it is more like a plug.

Go ahead and grab it good with a pair of pliers and twist it out. Vice grips work too, and you can squeeze it pretty good.

The main is directly below that (obviously). the gas actually flows thru the main, then across a small passage and up thru the pilot jet into the carb bore.

Once you have all your jets and rubber out of the carbs, take your spray cleaner and fire it up into the pilot hole while looking down the carbs bore. You can VISUALLY VERIFY that the fuel is squirting into the carb thru ALL of the small holes at the top of the bore. You may need to re-insert the mix screw (without the rubber oring) and close it down to 2 turns out to get a nice fine pressure spray through the pilot circuit.
Make sure all holes in the bore squirt when spraying thru thier corresponding ports in the carb bottom.

You can use a steel brush bristle to clean out the pilot jets. just poke thru the crud then spray thru them with carb cleaner.

Good luck! and remember, the carbs need to be REALLY clean.. ON THE INSIDES!

Wow! Thanks man! That definately makes me feel alot better about trying to get those suckers out with a set of pliers i was just worried about doing something wrong and breaking something! Will do that right now before i go to work!

haplo_84 wrote:

Wow! Thanks man! That definately makes me feel alot better about trying to get those suckers out with a set of pliers i was just worried about doing something wrong and breaking something! Will do that right now before i go to work!

No problem

REMEMBER: The most important thing you can do, is to squirt the cleaner (via straw) thru the pilot passages, and MAKE SURE that it squirts out nicely of all the holes in the carb bore.

This COMPLETELY ELIMINATES the need to guess later if your carbs are clean or not.

Also, use a good fuel filter before turning on the gas to your nice clean carbs.

Cheers!

Just got finished doing that. Thanks alot for the help. There was so much crud i still couldn't get them out, so ended up drilling into the top and using a screw extractor on them.

Either way though i guess i'll just have to wait to test them out till i get my new caps from bike bandit. I guess that'll be another week or so. I was hoping to test them out this weekend.

Oh well, shit happens as they say!