81 kz650, accelerator pump parts problem

Okay, cleaning the carbs on my 1981 CSR kz650. This bike came stock with an accelerator pump on the carbs.

The way it works is -- an extra linkage was added to the throttle's butterfly pulley that operates a diaphragm in the float bowl of carb #2.

The four float bowls are connected by rubber tubes, and each tube connects to an extra vertical shaft that's at the front inside each float bowl -- this shaft shoots gas into the carb throat, hence a 'gas boost' or 'accelerator pump' effect.

Well this shaft, from bottom to top, is filled with a ball bearing at the bottom of the shaft; a small brass piston; and a circlip at the very top.

The circlip allows the brass piston to rise upward when the accelerator pump flows the shot of gas into the shaft and into the throat of the carb; the circlip also *stops* the small brass piston from flying out the top of the shaft.

I LOST ONE OF THE LITTLE CIRCLIPS.

Anyone know if Kawasaki still sells these little C-shaped circlips? The darn things are made of spring steel, so they achieve velocity if they get away from you when you go to collapse the circlip to fit it into the top of the shaft and they're so tiny, once they fly forget it it's gone. You can barely see the darn things when they're right in front of you.

Anyone know of a vendor for these?

I'll tell you what, NEVER will I remove the circlips again during a carb clean. I'm surprised I got 3 out of the 4 back together, they're slightly smaller than the size of the letter 'C' on your laptop keyboard.

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The ziploc bag with a bowl inside occurred to me. I may do it just to get this last carb back together. I found I needed a fair amount of open air space above the carb bowl as I navigated my miniature needlenose pliers used to compress the circlip and insert it into the shaft in the carb bowl.

I thought about using a strong magnet to find the clip yesterday so I left my work area (inside the house with the TV on) undisturbed to look for my magnets and couldn't find them. The clip is a ferrous metal because the tip of my pliers is magnetized and the clip attached itself readily to the pliers.

Martin thanks for the tip about the rebuild kit, I will probably buy one of those if my Kaw dealer doesn't have the part, then never ever disassemble this accelerator pump valve again as long as I see it's moving up and down in shaft and responding correctly to negative and positive air pressure applied to the input nipple that's at the bottom outside of each carb bowl (this nipple routes accelerator gas to this shaft).

I debated whether to remove the 4 clips at all. I checked each shaft and its valve responded correctly to both negative and positive air pressure. But since the shaft is routing the accelerator pump's gas charge, I figured "I'm cleaning the carbs, for completeness I will disassemble and clean these shafts even though they act fine."

Never again. Paying $3 for a tiny circlip that flies out the door like a cheap whore you just paid is not my idea of a good time.

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Good idea, before I set out to re-install the circlips yesterday, I couldn't figure out how to have enough room for the range of motion of my hands and my tools. I will try it when I get the clips and post back.

martin_csr wrote:

The part is listed as Active at Kawasaki.com, so it might be available. But I'd be kinda surprised if it was... you never know though. RonAyers lists it at $2.99, ouch, but who knows if they really can get it. FYI: a rebuild kit from Z1Enterprises.com includes the clip.

92037-1123
Description: CLAMP,SPRING,CHECK VL
Package Quantity: 1
Item Status Code: Active

RonAyers.com
Mfg. Part Number: 92037-1123
SKU: 1084934
MSRP: $4.82
Your Price: $2.99

My local Kaw dealer wants $6.00 (and a share of my IRA distributions starting at age 65) for one of these suckers. At least they can order them. 100% will be doing the reassemble inside a covered bag of some type. Next time I get a desire to clean the accelerator pump lines I'll just spray some carb cleaner in there.

I finally got around to ordering these Martin, since the shipping was $5 and they fit a few bikes, I bought 5 of the spring clips at $2.99 each from RonAyers.com.


HEY DUDE THANKS because -- I cannot even FIND this part in the fiche on Kawasaki.com !!

And I have the parts list for the 1981, the 1982 and the 1983 Kz650 CSR H1, H2 and H3. NONE of these parts diagrams show this part or list the part number in the parts table (p/n 92037-1123
"Description: CLAMP,SPRING,CHECK VL")


WHERE DID YOU FIND THE PART NUMBER?

And is there in fact an *accurate* carb parts diagram for the 1981 CSR 650, because neither Kawasaki.com nor my factory parts list even SHOWS the accelerator pump and the valves in the float bowls.

THANKS for saving me here Martin, and where on earth did you find them?

They might also be on one of these websites too:

Carb Parts
www.nrp-carbs.com
www.motorcyclecarbs.com
www.carbparts.com
www.carbkitscapital.com
www.pjmotorsports.com
www.jetsrus.com
www.sportingforless.com/servlet/the-Carb-repair-kit/Categories
www.oldbikebarn.com/Motorcycle_Parts/Carb-Rebuild-Kit
www.cycleorings.com/

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Here is a pic of the accelerator pump parts - it is from a parts list for the 650 H series models. Hope this helps.

Mcmaster has all sorts of retainer clips.

5mm external e-clips sell for about 3$ for a 100 pack.
www.mcmaster.com/#circlips/=bgac6a

Steve