One more attempt to get this running correctly

HA! Found the kickstand switch issue, after all this time! Tested kickstand and clutch switch independently with multimeter and they both operated correctly. That led me to chase down wiring harness issues. The plug on kickstand switch wiring felt loose. I de-pined the female end and carefully worked the connector - don't squish it all the way down - then reassembled. Eyeglass screwdrivers and safety pins are your friend here. You need to push from the wire side while working the tab from the connector end and have patience. Hope this helps someone working to keep these 40yo beasts alive.

Time to check the pressures and do a quick burn around the block. Then a carb adjustment and a much needed bath for the ol' girl.20260410_102329.jpg20260410_102435.jpg20260410_102608.jpg
 
I am ready to take this baby out, the HD road king just doesn't get the juices going like the ZL
 
My petcock was really difficult to turn, I opened it up and the disk with the 4 holes in it was all boogered and bunched up. It was time to clean up my mess and hmmm.
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The parts shown from L-R are the Main Jet, Emulsion Tube, Pilot Jet, and Jet Needle. The Jet Needle as shown is the end that goes in first. I saw a case where this Jet Needle was installed backwards and forced into place. It bent the emulsion tube and the Needle Jet. Try finding these parts!
 
Thanks wuputt, I found the jet needle for a princely bundle of cash. Too much clutter on my bench and one rolled. I found it upon cleanup, should have heeded Marks rebuild thread and laid down the towel first. Im almost there with the bike now.
 
I can’t tell you how effective it is to find a lost item by purchasing its replacement! I’ve done it too many times to count.
 
Thanks guys, makes me feel better that I'm not the only one.:laugh:. I have a sneaky suspicion that that spare won't ever be needed.
 
It seems to be a fuel supply issue. Ran great on my auxiliary tank, sync'd the carbs, put on tank drive down the driveway and out of gas symptoms, same on prime. Push uphill back home for a bit before getting the wife and tractor for a tow. No difference if gas cap was off or on. Changed the feed hose to the yellow figured a kink was in the old braided rubber plus i can see what's going on. Blew through the tank hose connections, check valve to battery drain hose seemed operational. Tomorrow I will pull the petcock apart again and make sure the passages are clear then blow some air into the tank vent. Frustrating.
 
Scratching my brain trying to narro.w down the possible problem, You are hitting the usual suspects. You don't have a inline filter right? You do have the small line from the petcock hooked to #2 carb correct? It will drive me crazy till you get it!!
 
No inline filter, petcock to #2 carb. The black rubber still seems pretty flexible, I thought it was kinking but that's not likely. I'll maybe get a chance to put some time into it this evening. Feels like I'm so close.
 
Another night another tow. Petcock worked flawlessly when I drained the tank.
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No water in the fuel. Ran for 10 minutes before I hooked up the tank and went down the hill for it to die. Time to eat then check some tank lines.
 
Tank vent is clear, tank is empty now and the gas is going into the mower. Need to tweak the connie/ZL gauge and I guess i will take the fuel tap apart again and remove the screen to check the passages.
 
Could it be possible that the fuel lines look and feel good but are being collapsed and pulled together by the vacuum? Just a thought.
 
What Furchin asked and did you check the petcock in the run setting with vacuum?
 
I didn't see gas flow in the new yellow line from petcock to carbs when it dies. Need to take that fuel tap apart. When I first got with the wife, the well water would just shut down in the middle of a shower. She said just sing a song and it will come back on:roflmao: It turned out to be a solidified chunk of sediment I found when I went to change the pressure switch.
 
Well, maybe you just need to sing kawasakis old jingle when you’re riding it! “Kawasaki lets the good times roll”.
 
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