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Trying to repair wore out Needle Jets/Emulsion tubes.

limeex2

limeex2

Forum Sage
Past Site Supporter
I found an unmolested Kawasaki 82 GPZ750. Believe it or not, I am going to leave it stock. Going through issues at the moment. First is getting it running properly. It has a problem that is common with diaphragm type carbs that over time, the needle wears out/elongates the metering holes of the needle jet holder/emulsion tubes. These tubes are unique to this model and have been discontinued.
The tuner has a source that could make these tubes, but that could turn into a circus. My idea, in short, was to use an industrial strength epoxy to fill the jet hole and resize to proper size. I was able to find 1 new tube so we have a model to use. My thoughts are that if the source can make new tubes, they should be able to get the proper sizes back.
The epoxy is Belzona 1111. It is used to rebuild industrial shafts, broken motor cases ect. It is compatable with brass and most chemicals and can be machined and worked like regular materials. I can find used carbs on E-Bay, but I will assume that the used ones are wore out too. Looking for ideas and input, Maybe our racing friends from New Zealand can chime in, they seem to have creative ways around many GS issues. Thanks!
 
How did you determine that the jet needles are worn out? They normally last the life of the bike, or at least, 50k+ miles.

BTW, no way I use epoxy.
 
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It's a fairly common problem. Intake vacuum pulls the needle into the nozzle and over time elongates the hole causing a rich condition. Honda V-4's are notorious for this issue. The previous tuner had used larger needles in an effort to compensate and it ran like sheet. I understand not wanting to use epoxy but I've seen crankcase fractures repaired with epoxy and not fail. We used to make odd ball main jet sizes by hand with precision drill bits. Read up on Belzona epoxy, pretty neat stuff Its compatible with brass and virtually chemical resistant. I emailed Sudco and they said its a Kawasaki exclusive, so no go. I am going to try Weblike in Japan when I can get more specs from the tuner. There's a used rack on E-bay for $200, so if the epoxy use failed, I would have another set of tubes w/needles and it would be pretty tough to be in worse shape than these. Bike has 44k, is bone stock, is in incredible shape and worth some TLC.
 
limeex2 said:
It's a fairly common problem. Intake vacuum pulls the needle into the nozzle and over time elongates the hole causing a rich condition. Honda V-4's are notorious for this issue. The previous tuner had used larger needles in an effort to compensate and it ran like sheet. I understand not wanting to use epoxy but I've seen crankcase fractures repaired with epoxy and not fail. We used to make odd ball main jet sizes by hand with precision drill bits. Read up on Belzona epoxy, pretty neat stuff Its compatible with brass and virtually chemical resistant. I emailed Sudco and they said its a Kawasaki exclusive, so no go. I am going to try Weblike in Japan when I can get more specs from the tuner. There's a used rack on E-bay for $200, so if the epoxy use failed, I would have another set of tubes w/needles and it would be pretty tough to be in worse shape than these. Bike has 44k, is bone stock, is in incredible shape and worth some TLC.
Click to expand...

And after just reading about rebuilt choke plungers from Jedz in the UK, i will probably try that update. The bike is running rich and would then eliminate that as a possible cause. I will speak with the tuner tomorrow.
 
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Lots of internet time netted much info as did Nessism on carb work. Found some similar nozzles that may have worked but would take considerable modification. Do-able, but probably very expensive. In the mean time I had been in touch with a seller on Ebay that was parting out a 82 GPZ. When the carbs came up for sale I purchased them. They are unaltered and I will use those, upgrade where necessary. There are always issues with new/old bikes, and I'll probably find more, but it's fairly unmolested so it shouldn't be to bad.
 
Used set were good, repaired, painted as necessary and got bike up and rolling. Runs very well, chassis is nice and tight. Put on about 100 miles on a nice fall ride before weather set in. Wish I could post a pic, not in my skill level.
 
I know factory pro has certain emulsion tubes, needle jets and needles. I haven't researched what they do have. They have a good CV carb techtorial and other needed CV information as well.
 
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