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This is the perfect example of why we don't recommend the rebuild kits. Many times the jet sizes are wrong too, lol. The replacement needle and seat assemblies many times leak right out of the box. Like you said, about the only thing you can count on fitting and working is the float bowl gasket...

It may also be putting out AC not DC current.

To make those "on the fly" idle speed adjustments easier, I've started pressing knurled "caps" onto the screw heads ..... The top remains open so you can still use a screwdriver on it ..... I use Presta valve stem adapters sourced from eBay (less than a dollar each) ..... I drill them...

I never bought any 3.5mm fiber plates, never needed any as all my clutches are the later type that use 3mm fiber plates. If you do the math, I think one more 2.5mm fiber and one more 1.4mm steel will get you very close to what you need. What you have stock is 7 fibers @3mm (21mm) + 6 steels...

Yes, the spring steel clip that holds the choke on can be bent to try and adjust how much the lever lifts the choke plunger, but before you do that, try this .... there is some play in the mount so loosen the screw and rotate the bracket to the left (CCW), then re-tighten the screw. That may be...

Although B8ES plugs were speced when the bike was new, BP7ES plugs were specced for the later models and it's accepted practice to use them in all models. They are a step hotter and have a projected tip. Both of those attributes should make them burn cleaner and lighter in color. So, if you're...

So, it was that too short Y-22 needle causing the issues. That needle can only work in the '70 to '73 carbs, as a replacement for the 4JN19 that was stock in them. If you're wondering why those early carbs used this shorter needle and the longer Z-6 needle jet, it was because the floor of the...

Yes, the measuring method is the best way to insure the amount of oil is equal in both forks. This is especially true when you do your basic fork oil change, a simple drain and refill, because you never get all the old oil out. And it seems the amount left in each leg is never exactly the same...

Yes, it looks like the timing chain is off a tooth. You should be on the "T" mark (TDC) when that little pin hole in the cam is pointing straight up (or straight down).

Well no, not really. Those are just stock '82 wires and plugs. What you want to show us is what's on the other end of them, your stator.

These forks work much better with slightly more than the stock amount of oil (about 5.7oz.) in them. I go about 6.5 oz., 7 if the forks were stripped and totally cleaned out (really, truly empty). Or you can use the old tried and true method of setting the oil level 6" from the tops of the tubes...

Yes, all the models with the headlight safety relay do that. Get the motor spinning enough so the alternator puts out some voltage and that will trip the headlight relay, whether the bike is running or not. Silly system in my mind. That's why I eliminated it on both mine, lol.

Yes, but it can be tricky. The holes in the ends of the later cams weren't finished off and sized exactly for the bushings. You have to do that and if you don't, you run the risk of splitting the end of the cam when you drive the bushings in because they're too tight. If you have a good early...

I'll admit that I'm very partial to the Pamco and have been running one for many years, almost since they first came out. Pete sent me an early one for testing and review, and it's never missed a beat. You'll need parts from your early top end to use it, namely the cam with it's internal...

I know what the light checker does but not exactly how it does it, lol. If you study a wiring diagram for your model, you will see you have the more complex 7 wire light checker. The R/W wire doesn't come from the fuse box, it comes from the starter/headlight safety relay. Instead, there is a...

Well, I suppose you could try the longer needle jets but they may not flow the same, especially when the throttle is closed. As far as cutting them down, take a look inside the top of your Z-4. See that step about 1/8" down inside, about where the o-ring groove is on the outside? That's the...

Which one cold starts easier?

Yes, low power to the coils, resulting in a weak spark, is apparently a common problem on old bikes. Although I've never done it, here's a write-up on adding that relay ..... https://wgcarbs.com/index.php/using-joomla/extensions/components/content-component/article-categories/89-coils I have...

So, what were the 5 little "fixes"? I think I see a bit of a "groove" ground into the top corner on the swingarm. A little off the MC mounts too I assume?

Yes, I noted that as well in that post.