Choke plungers causing rich condition?

Hey guys,

I'v been chasing low rpm running and starting/warm-up issues ever since I got my 77 KZ1000 running late last year. It's taken me awhile to work through a multitude problems. Found leaks at carb holders, dead plug caps, poor points and condensers.

I'm now very confident in the ignition system. I'm also quite confident in the work I've done to the carbs, with one exception; the choke plungers. All I've done is replace the o-rings and reinstall them.

I have consistently rich #1 & #2 plugs while #3 & #4 look good. My question to you is, would leaky choke plungers cause a rich running situation like this? And are new plungers available? Z1E does not list them and my Kawasaki dealer doesn't open until Tuesday.

The bike is 100% stock and original.

Thanks,
Ross

...77 KZ1000...very confident in the ignition system. I'm also quite confident in the work I've done to the carbs...consistently rich #1 & #2 plugs...would leaky choke plungers cause a rich running situation like this? And are new plungers available?....

Possibly, and perhaps ethanol might contribute toward deterioration of the pads on the choke plungers.

Vaguely recall Wired George having mentioned that the pads were not separately available, and he had perfected a special procedure for making and fitting new pads to the choke plungers, when needed.

But first, if not already done, would perform clear tube tests to assure fuel level inside float bowls is within specs.

Good Fortune!

It is possible for the enrichener plungers to cause extra mixture to leak past them, however it is not very likely, as even when not seated fully, they still prevent the air flow that draws the fuel mix into the carb bore.

I would first check the fuel levels as Patton mentioned, and them perform (or have performed), a good proper vacuum syncronization with a very accurate tool.

Be sure to properly tune your mixture/air screws before the sync procedure.

Good luck!

I have set the float levels using the clear tube method. They were all dead on prior to finding all of the other problems. Then I removed the carb rack again, float levels were all spot on. Then I lowered the levels on #1 & #2 to about 6mm below the bottom of the carb body (spec is 2.5 to4.5mm) to no effect. This was done on the bench with carbs dead level. The plugs still show a very rich condition.

I use some inexpensive vacuum gauges to synch the carbs. I believe they are good enough. I've used them on my kz900, and it runs awesome.