Originally Posted by Mucky_Waters

So let me understand this,,,, if you drill out that hole the bike is suppose to start better. Right?
If that's the case, why didn't they just make it bigger in the first place?

Originally Posted by TNC

LOL!...Mucky, not trying be a smart aleck, honestly, but by your statement no manufacturer would ever make a mistake or misjudge a component's funtionality in the final product. Especially on a street legal bike, it has to meet emission standards, and those standards include what emissions occur during startup/warmup. Kawasaki apparently misjudged the optimum size for that jet. This isn't that uncommon over time. When I worked part time as a mechanic at a local motorcycle shop, a new model of KZ650 road bike had cold start problems...not every bike, but enough that we got lots of complaints. Finally we got an "under-the-table" fix mentioned by one of their techs about drilling the starter jets slightly bigger. There was never a recall or bulletin. If Kawasaki had given this as an official fix, it would have violated the emission ratings of the bike...at least that was under-the-table message. The fix did indeed address the cold start problem.
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Originally Posted by IDRIDR

Did you feel any resistance while drilling?
If so, you should have felt it blow through the jet and bottom out, IIRC.

Originally Posted by drm

Ok...who put the security torx on the tps sensor?

Originally Posted by drm

After thinking about it during the last 3hrs on the interstate, I guess my other option was to unplug it at the harness and take it with the carb.

Originally Posted by philp38

Update....my bike started perfectly after drilling the jet. I also opened up the air fuel mixture screw and set it at 2 and a half turns out. It idles much better and doesn't seem to be as cold blooded as it did before.