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1976 KZ400 jetting w/ pod filters 23 Apr 2017 15:05 #760058

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I wouldn't jump to a conclusion that there is a stator problem. Instead, run the charging system tests in the Kawasaki Service Manual to diagnose and pinpoint the source of the problem. Keep in mind the problem could very well (and more likely) be in the rectifier or in the regulator or even in the wiring or a bad connector. My KZ650-C1 had a charging problem, and the tests in the manual very quickly identified it as a bad diode in the rectifier. I replaced the rectifier and presto / chango no more problem. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
The following user(s) said Thank You: GPz550D1

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1976 KZ400 jetting w/ pod filters 23 Apr 2017 16:03 #760060

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alinaaseh wrote: Hi all.

I've come to admit that I made a very rookie mistake and have wasted your time. After ensuring that the air jets were in the correct spot (they were), I realized something that I should've realized long ago.

The carbs have an idle adjustment screw that changes the position of the butterfly valves, and it was locked up until today. I admit - I never once thought to tinker with it, as I believed it was part of the assembly that held the carbs together. A blast of wd-40 and a quick soak freed it right up.

I'm embarrassed that I spent so much time fiddling with jets when the solution was right there all along. I am, however, excited that the bike rides, and looking forward to tuning the carbs to their fullest extent.

Thanks for tolerating my idiocity. Much appreciated.


Damn Ed!
He didn't even make it to summer.


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2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


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1976 KZ400 jetting w/ pod filters 23 Apr 2017 16:57 #760062

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:laugh: :laugh: :laugh:

I'm glad he found the issue so he wasn't reduced to riding a Yamaha all summer. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Last edit: by 650ed.

1976 KZ400 jetting w/ pod filters 24 Apr 2017 07:45 #760121

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Nebr_Rex wrote:
I was replying to Patton.


I was just interested in seeing your project and was bummed the link didn't work.

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1976 KZ400 jetting w/ pod filters 24 Apr 2017 07:47 #760122

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On my buddy's 400, we had charging problems too, initially, which caused some sputtering and dying. Ours turned out to be the regulator.

We should probably mention, for anyone interested, these settings are only for the 1976, and probably the 1975, and a few 1977 Kz400's which use rigid piston slide CV carbs. Most 400/440's use diaphragm CV's.

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Last edit: by loudhvx.

1976 KZ400 jetting w/ pod filters 24 Apr 2017 09:25 #760130

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That's reassuring, at least I know it's not just a fluke on my bike! Just did a quick dynamo test and the results seem telling. With bike not running, resistance between all three wires reads ~1 ohms. With bike running, AC output reads 3V. I'll post in the electrical subforum to triple check, but to me, this means the stator field coil is fried.
1976 KZ400 D3
Ft. Collins, CO

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1976 KZ400 jetting w/ pod filters 24 Apr 2017 09:40 #760132

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Don't jump to that conclusion based on a single stator voltage test. If you look in the manual it will detail how to do the test properly.

You have to disconnect the regulator and jumper the connections to apply voltage to the field coil. I *think* you jumper the brown wire to the green wire. That applies full voltage to the field coil. But verify that with the manual.
Then you can measure the AC coming from the stator.

The stator windings and field coil are two separate things.

EDIT: I will repost this in your charging system thread, to keep everything related in the same thread.
www.kzrider.com/forum/4-electrical/60575...-output-test-results

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Last edit: by loudhvx.

1976 KZ400 jetting w/ pod filters 24 Apr 2017 18:09 #760173

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loudhvx wrote:

Nebr_Rex wrote:
I was replying to Patton.


I was just interested in seeing your project and was bummed the link didn't work.


try this

www.dotheton.com/forum/index.php?topic=39120.0

or copy and paste

edit: I tried also and it doesn't work you'll have to copy and paste.


.


.
2002 ZRX1200R
81 GPz1100
79 KZ1000st daily ride
79 KZ1000mk2 prodject
78 KZ650sr
78 KZ650b
81 KZ750e
80 KZ750ltd
77 KZ400/440 cafe project
76 KZ400/440 Fuel Injected

www.dotheton.com/forum/index.php?topic=39120.0


.

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Last edit: by Nebr_Rex.

1976 KZ400 jetting w/ pod filters 24 Apr 2017 20:41 #760184

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That's an insane project ! Thanks for the link! Great read. :)
I saw some HEI modules in there. I don't know if you saw my updated notes on the 4 pin, but there are a batch of newer modules that don't really follow the rules of the original design. They now use microcontrollers instead of an MC3334 chip.
s3.amazonaws.com/gpzweb/Ignition/HeiModules/HeiModules.html

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Last edit: by loudhvx.

1976 KZ400 jetting w/ pod filters 23 Jan 2019 16:32 #797383

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I'm doing research on my 74'/75' KZ400 carbs (CVB36's marked 746E) and came across this thread, amongst others on the subject of getting these carbs to work properly with pod filters (haha) ... I purchased a Keyster rebuild kit KK-0139F which came with all new jets except for a pilot jet (oddly enough, the carbs did not originally come with pilot jet installed, which only begs more questions about what the PO was doing... anyways...). The kit did come with a new slow jet with the emulsifier tube; a #40. It appears to be a common issue locating replacement pilot jets. I saw mention of a Keihin p/n 99101-124-xxx (i.e. 99101-ZF5-xxx), available from Power-Barn, etc, and I was curious if anyone has purchased these to confirm they fit???

For what it's worth, I've found some part fitment/cross-reference information saying that 99101-124 is the Primary Main jet (as opposed to the Secondary Main jet) for multiple later model KZ carbs including but not limited to certain 78-80 KZ400 A/B/C, KZ440's, KZ250, etc. Not sure if the "Primary Main" and "Pilot" jets are somewhat analogous in certain instances concerning these Keihin CV carbs...

Jetting information from thus far...
Removed from my CVB36's:
Main Fuel = 125
Slow Fuel = 35
Pilot Fuel = not installed
Starter = 72
Main Air = 60
Slow/Pilot Air = 90

Keyster Kit KK-0139F:
Main Fuel = 135
Slow Fuel = 40
Pilot Fuel = not included in kit
Starter = 60
Main Air = 60
Slow/Pilot Air = 110

Sizing Suggested by LOUDHVX from notes on 6/20/07, 76'KZ400-S2, EMGO pods and cut 2-1 exhaust:
Main Fuel = 140
Slow Fuel = 37
Pilot Fuel = 64
Starter = 68
Main Air = 60
Slow/Pilot Air = 90
(Note that slightly different jetting was given by LOUDHVX in post on 4/25/06, 76'KZ400-S2 with Uni pods and stock 2-1 exhaust)

As for me and my planned setup on this bike, I'll have Uni pods and an open/cut 2-2 exhaust. I guess my initial target will be to get close to the values mentioned above by Loudhvx… As for the pilot jets I mentioned earlier (Keihin 99101-124), this jet is only available in sizes > #48... I suppose I would look to get a size of ~50 and/or 60, to accommodate my setup.

Other adjustments I think I can anticipate: a #140 Main Jet should be easy to come by (Keihin p/n 99202-601). I can put the original #72 Starter Jet back in. Curious if anyone thinks the #110 Slow Air jet is too big? If so I can put the original #90 back in; otherwise not sure if there's one readily available in some intermediate size e.g. #100 (anyone know of something that will fit, or closely fit with a little modification, perhaps a Mikuni BS30/97 Air Jet? Measurement comparison appears about right).

I wish Keyster would list p/n's of the individual items in there kits. Would've made this much easier; eliminated some of the guessing game.

I would appreciate any help. You guys were a instrumental on my KZ650 project. Thanks!

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1976 KZ400 jetting w/ pod filters 24 Jan 2019 09:38 #797431

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We are talking over 10 years ago, so my memory is sketchy, but as I recall, we may have used pilot jets from an early 1970's Honda CL350, as we had one with a blown up motor back then and we scavenged parts whenever we could. If you read my posts from back then, it might confirm the Honda jets. If I recall, the Honda Keihins had brass floats and rubber diaphragms which are different from the piston-slide, foam-float Kz400 Keihins, but the pilots would swap over, and maybe some of the other jets too.

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1976 KZ400 jetting w/ pod filters 31 Aug 2019 22:19 #810170

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Hi there , I’m sure this thread is pretty old but do you have those Mikuni’s still for sale? I ultimately want to but those on my ‘78 KZ400B. Please let me know.

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