GS1000S Insulator Replacement | Z1000J OEM Adaptation and TMR Carburetor Synchronization & Cleaning

It seems I’m experiencing the trials and tribulations of vintage bike ownership…
The more I look at it, the more I wonder if it’s okay? I’m working to overcome this questionable condition (*´ω｀*)

Adapting the Z1000J intake manifold to the GS1000S

Z1000J=P58mm
GS1000S=P60mm *Note: GS1000 comes in two types depending on carburetor (VM or BS), so be careful

Since the pitch didn’t match, I used a Nakanishi tool to elongate the bolt holes.

Kawasaki 16065-1135
It’s extremely fortunate that this is still available today.

Since this is the round rib type, be sure to check the spigot.

The old one is completely cracked. The inside was swollen and deformed (*´ω｀*)

I secured it with a flanged (steel) mount for solid surface contact.
That’s one less thing to worry about.

I’ve been compiling parts information on note recently.

Throttle and clutch wire replacement

The clutch wire is ADVANTAGE GSX750S model 582-S11
With an outer length of 1160mm, it works great even with raised handlebars.

I want to synchronize the TMR, but first let me clean it…

It’s been used quite a bit, as you can see from the condition.

First, the funnel wouldn’t come off and I panicked… I managed to get it loose with a steering wheel hook wrench ( ﾟДﾟ)

I was amazed by the buildup from backflow… I enjoyed watching the jets and seeing how they age and change color.

One thing leads to another, so I’ll finish it up while I’m at it.

I’ll stop here before I get too deep into it.

I’ve synchronized the carbs.
I was able to confirm the current settings, which is great.
I also replaced the O-rings.

The throttle holder is stiff when closed?

Depending on the throttle sleeve winding diameter and carburetor compatibility,
you may need to shorten the throttle inner wire.

Laying it out externally first makes the work go smoothly.
Before worrying about wire length, the throttle is super stiff when the switch box closes.

Looking closer,
the upper inner width of the switch holder is narrow, and the throttle wire ferrule is slightly long and makes contact.
I cleared it by sanding it down with a belt sander.

I also added a POM spacer on the inside.
Things are gradually improving.

Once I start, there’s no end to it, but it should be much cleaner (*´ω｀*)
To be continued.