Can you help me solve a carb. issue on a 2001 KZ1000 Police bike I recently purchased?

Question

I bought a 2001 KZ1000 at auction. Would only run with choke rod out. Even then, acceleration was flat and no power. Push in choke and it will only stay running with feathering. I dismantled the carbs and cleaned thoroughly. There was no sign of wear or varnish build-up in any of the 4. I reassembled(each carb with it's own parts was kept separate as well as detailed photos of each carb and each step of the tear down.) I installed the carbs and still seem to have the same issue. There is a vacuum nipple or port on each of the 4 carbs. From the vicinity of the front forks and under the tank, there is a vacuum line coming to the carbs and has a T in it to allow it to connect to 2 of those vacuum ports. There is also a vacuum line coming from the fuel petcock to a 3rd carb. I found 2 long hoses coming from the underneath side of the fuel tank, 1 slightly larger in dia. than the other. (Not counting the main fuel line to the petcock.) That leaves 1 vacuum port open which I capped. There seems to be no leakage from the petcock with hoses removed. Other than in the PRI position. I would appreciate any advice as to where these hoses all go, and what to look for that is causing this problem. This was a Phoenix Police bike and seemed to be well maintained with 60k on it. Thanks. I am quite mechanically inclined and experienced with engines, but I am not well versed on bikes. Kawasakis in particular.
Thanks.

Answer 1

most vacuums are hooked to the petcock and one is prolly jus a vent. whoever worked on it mite have disconnected them 4 a reason. some bikes run better with the vaccum line off the petcock and just hangin to the side to pull fresh air...reason being is because the bike may have been runnin a bit rich at 1 time so the mechanic pulled the vacuum line off so it wud get more air.this is a very quick and effecient way to quickly fix a rich ruinnin bike.id just keep an eye on the spark plug and it'll tell you exactly what you need to kno.it prolly just needs the carb needle dropped or jet tightened

Answer 2

Sounds like it's running way too lean. Most 4 cylinder Kaws of that era had two vacuum hoses from the nipples on the top of the rubber manifolds between the carb and engine (1&4 I think), which connect to a T fitting and the single hose connects to the air control valve of the clean air system above the engine. The vacuum petcock hose attaches to carb #2 at the carb body itself. The 2 long hoses are vent hoses and connect at the air cleaner and connect to the vent ports at the carb body on #1&4. The 2 nipples on the bottom of the rubber manifolds between the carbs and engine are plugged and only used when syncing the carbs. I may be wrong, but I bet you have a vent hose connected to a vacuum port, leaning out the mixture.

Answer 3

Im in phoenix and those bikes go through HELL before they sell them.After the force is done with them they get used as trainer bikes and part of the training is they have to DROP the bike at 25 M.P.H.! After ll that they finally sell them. However send me an E mail at [e-mail] and I can help you out and get your bike running.I make house calls!