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Discussion Starter · #361 ·
well yeah...never actually heard of a problem with the starter motor on a Kawasaki, but the starter clutch always seem to be problematic. Hopefully not the case with yours.
I'll have to look at the symptoms of a bad starter clutch. My rationale with it being the starter motor is that its exhibited the same symptoms as my various cars that have had failing starters.
 

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Discussion Starter · #362 ·
Got around to installing the new starter.

I used some (fill with solder style) cable ends and crimped them on with a swaging tool. An ichiban solution to be sure, but it works well.



The new starter was a much tighter fit than the old one... specifically the fitment at the collar just in front of the o-ring. Yes I lubed it. I wound up using a long wooden dowel and a rubber mallet to tap it into place. I tapped it back out just to make sure I wasn't getting it permanently stuck. After bolting up, I tested the system and it works perfectly.

 
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Discussion Starter · #363 ·
...

 

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Discussion Starter · #365 ·
Geez..Ya haven't hung up yer headers fer good?
Nope...

It's an vintage hand bent exhaust for a Z1/KZ. It's likely a 70s yoshimura piece.

It's been glass bead blasted to check for leaks as well as repainted. It has fresh baffles as well.



I'm not sure if it will be a performance improvement over my vintage kerker with race baffles.... but the cool factor more than makes up for it.
 

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Discussion Starter · #366 ·
Fitted the exhaust. I hate fitting exhausts... they're such a pain in the ass keeping the collars in place, getting everything set in place, cramming your hand in there to tighten everything down.



I also changed the oil, because unlike the kerker I have, I can't change the oil with this exhaust mounted.

Here's a picture of it with the yoshimura emblem placed on it. The old ones were glued on, not riveted so I need to get some permatex black to secure it to the muffler.



I do still have to make a hanger for the muffler section as well as finding a good clamp for where they join.
 

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It will be interesting to read what you think once you get a chance to put it through it's paces. The smooth arc of the Yoshi makes sense to me for moving gas efficiently. Visually I like the fit of the Kerker but it makes me wonder about the performance compromise when comparing it to the Yoshi design.
 

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Discussion Starter · #368 ·
It will be interesting to read what you think once you get a chance to put it through it's paces. The smooth arc of the Yoshi makes sense to me for moving gas efficiently. Visually I like the fit of the Kerker but it makes me wonder about the performance compromise when comparing it to the Yoshi design.
Agreed.

I think... instead of making a bracket, I'll have my machinist make an elbow that slips between the collector and muffler that will angle the muffler up to the mounting point. That would not only solve my mounting problem, but it would also give it a bit of an upward sweep.
 

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Discussion Starter · #369 ·
So I got it to fit.
The previous owner had replaced the header studs with hex bolts. They looked good but made it a huge bitch to mount exhausts.
I replaced all of them with stock studs/washers/nuts. this let me loosen the exhaust enough to mount it in the correct position. I still need to go get some heat proof adhesive to mount the yoshimura badge.... but that's not until after I cure the header paint. It smokes like crazy right now with the fresh paint.

 
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Discussion Starter · #371 ·
So I had a slight exhaust leak and took the opportunity to install new half-collars (the spacers that sit against the exhaust flange and the exhaust, pushing it against the head).

I had this issue with the old half-collars and now with the fresh ones too:





you can see that the flange isn't sitting flush against the head. When I inspected the crush gaskets, they were all well sandwiched meaning I was getting good contact. (I put another new set of crush gaskets on when I replaced the half-collars).

I think this may just be down to the lip on the yoshimura headers being thicker than on the kerker? I suppose I could get another set of half-collars and have them cut down slightly?
 

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Discussion Starter · #372 ·
Rode to work almost every day this week. Had some intermittent issues where I'd lose a cylinder. I think it was just a loose plug wire to boot connection... we will see. I also switched over to a set of denso plugs that I used for a few months a few years ago.
Ran really well today.





Now I need another one of Matt's belly pans.
 

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Discussion Starter · #374 ·
Ok nerds... I haven't ridden since re-sealing the leaking generator grommet in may 2020.

To motivate myself, I ordered some yoshimura carburetor parts and a PMC easy pull clutch kit. Should be shipped out from Japan tomorrow.
 

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Discussion Starter · #375 ·
DHL delivered the stuff today:





The yoshimura kit was straightforward enough to fit. I will have to rebalance the carbs though, as you need to remove the slides and jet blocks.

Its actually a really ingenious design, we will see how it performs in real life.



I did go with yoshimura's recommendation on jetting, which meant I had to clean out some solidly clogged jets I had in my stash.



I also pulled the old clutch actuator in preparation for installing the new one. Stopped to charge my phone because I use the Google translate app to double check the instructions.

 
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Discussion Starter · #376 ·
Got everything together and back on the bike.

I vacuum synced the carbs, even though SUDCO recommended bench synch only... we'll see if I need to go back and do it over.

Still need to check the air idle screws. I want to double check the timing too... even though its a dyna unit.

After that its a matter of riding it long enough to clean the plugs and get a reading.


I was getting the bike ready to sync in the driveway and a construction company project manager/exec/supervisor ran over to me all excited. Wanted to let me know about a bunch of his buddies who have old bikes, trials bikes, and his collection of museum quality 80s superbikes... pretty good day
 
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Discussion Starter · #377 ·
So took the bike out for a short trip to get some fresh fuel. Felt great, we will see how my rejetting, new needle, and balanced carbs affect the fuel mileage and plug color. The plugs probably need a few more miles to get cleaned up before I do plug chops.

Even better is that the gas station down the road from me has ethanol-free gasoline.

 
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Discussion Starter · #379 ·
Thanks for the tip
 

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Discussion Starter · #380 ·
So fuel mileage is up to 35mpg, mostly riding at 75-80mph.

I'll consider that a big win.

I'm still messing around with throttle cable adjustment... I can never quite get it as "tight" as I'd like. I may have to pull the carbs off and move the cables to the next holes on the throttle plate.
 
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