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New Member G'day Guys! New member with FZX250 Zeal '98

Discussion in 'New Members Say Gday' started by Ben Jammin’, Jan 9, 2018.

  1. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    yep same product
     
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  2. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Cheers @maelstrom :drinks:
    I just purchased the Zeal carb kit from your link.
    I took out number 3 o ring, and found it wasn't completely circular!
    I'm hoping that the seal kit solves my problem with the erratic tickover???
    :D
     
  3. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    So, I read on here somewhere that the Zeal needle clips should be set in position 3.
    EFC27B32-1F34-4E86-A3B1-3C74A443CF81.png
    All mine seem to be set on the lowest needle position. (1 or 5, I’m not sure which way you would count from)
    Thus:
    7057A576-2AAB-4F1D-8CDA-03BFFD2EB6FF.jpeg
    I’m waiting for my seal kit to arrive from litetek, so I want to have everything set as standard for when I rebuild the carbs.
    Do I adjust all the needles to the middle position?
    :idk:
     
  4. GreyImport

    GreyImport Administrator Staff Member The Big Cheese Contributing Member

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    Affirmative :D
     
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  5. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Thanks Dr Grey! ;)
    I think I've got some kind of a blockage in my pilot air circuit on carb 1. (hunch, due to it firing on choke, and then stopping firing off choke)
    I've carefully poked and clean all orifices, and when I blew carb cleaner through the idle jet hole, (with the jet housing removed) I got cleaner squirting out of 1 of the 4 tiny holes just inside the butterfly.
    Where do the other 3 holes connect to, and how do I access them?

    All other holes I've found the 'in and out' and got a clear passage...... but I thought the idle jet channel, should come out of the single hole on the engine side of the butterfly, along with air from the air jet??? (so that there's fuel when the throttle is closed) :idk:
     
  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    The 1 hole is for the idle mixture screw, for that cylinder to idle, the rest only open when the butterfly open's

    There is a press in alloy plug that can come out to allow access to the rear of the other 3 hole's
     
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  7. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Cool, I saw an alloy dooberrywhatsit in the float chamber, one of them has a piece broken off the edge. I didn’t realise it was a plug.

    So the single hole should connect to the idle jet (via the setting of the mixture screw) and also to the pilot air jet in the mouth of the carb at the other end right? (So there’s a fuel/air mixture bypassing the butterfly on tickover)

    So it’s definitely weird that I’m squirting cleaner in the idle jet hole and it coming out on the closed side of the butterfly? Doesn’t make sense!

    I’ll pull the plug and check if the blockage lies within.... :thumb_ups:

    Thanks again for the ongoing support guys!
    I will get this bike going! :neo:
     
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  8. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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  9. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    So I took a calculated risk, and answered my own questions! ;)

    I put a coach screw into the plug slightly, and wiggled and pulled gently, and the plug popped out. :thumb_ups:
    79812A0E-8385-4F57-B1E5-B2233E3D24B5.jpeg
    As expected there was some ‘crud’ in the hole, partially blocking the ports, and the slot on the bottom of the alloy plug was completely full of crud.
    The slot is now clear:
    66C427C9-5B2C-4F91-80A3-3B37202CCFDE.jpeg

    However, it seems that there is another ‘outlet’ from this chamber on the mixture screw side, which provides the path to the mixture screw, and then onto the single hole behind the butterfly that provides fuel/air on tickover.
    I put a piece of thin wire in the port, and can see it down the mixture screw hole:
    227EEC97-E1C4-4499-AF31-6C0BAC4EC182.jpeg
    But because the slot on the plug was blocked, I’m assuming that’s why No.1 stopped firing on tickover.
    Or at least I’m hoping! :D

    How long does shipping normally take from Thailand?
    I want to rebuild this thing now!!!!
     

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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    That must be it, the corrosion was not allowing fuel to get to the mixture screw
    Postage is fairly quick from Thailand, usually between 7 and 10 day's
     
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  11. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    I think I’ll just pitch a tent near the postbox!!! :prankster:
     
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  12. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Oh no don't do that. Aus is usually 14 to 20 days, sorry. My67XR must have got his quickly in the great lucky dip of the world's postal service.
     
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  13. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Sorry, I didn't get all of that.........
    The wifi here at the front fence is pretty poor, and my camping light just ran out of batteries!
     
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  14. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Success! :party:
    I fitted my new carb o rings, set all the needle clips to position 3, and she fired up on all cylinders! :cool:
    Hot header pipes on choke, and they stayed hot when I turned the choke off. It sounds weird hearing it running on all four finally! ;)
    There was a noticeable bogging when I revved it though, almost stalling, so I took the mixture screws out half a turn each. Then another half turn, and another half turn until I got to 3.75 turns each.
    But she revs sweet and responds well now!
    I’ll take her for a quick blast to the garage soon, to see if I can finally get a blue slip? When I get her home again I’ll pull the spark plugs and see what sort of colour they’re running at.
    It just seems a bit odd to have the factory setting of the mixture screws at 1.75 turns out, but ending up at 3.75? I know it’s only a starting point, but 2 extra whole turns is a long way off, no??? :idk:

    Anyway, thanks again everyone for the moral support so far! I couldn’t have done it without y’all! :drinks:
     
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  15. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Stupid question but, where should my clip position be, considering that there are plastic shims under each clip?
    Do I just ignore the shims and place the clip in the middle position anyway? How does it work?
    A7F5329A-80ED-4CDE-980A-9177BE01A61F.jpeg
    Or should I take the shims out???
     
  16. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Standard is clip in middle position with the spacer under it.

    If you remove the spacer entirely the clips will not hold over time.
     
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  17. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    As @Linkin said clip in middle notch on needle, use with spacer.

    With the bogging, what is your fuel height ? 10.5mm above the line ?
     
  18. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Thanks guys. I did put the clip in the middle notch as previously suggested by @GreyImport. But it only started to respond with the mixture screws set at 3.75 turns. However still not running well enough at all rev ranges.
    That’s why I thought I’d check about the plastic spacer.

    I think the float/fuel height needs setting now as the floats are around 12mm, which puts the fuel height around 1mm below the line! Far too low.
    I guess the last ‘expert’ put the clips higher instead of addressing the float/fuel height???

    Oh, the good news is, it passed the blue slip! :dance2:
    But I just wasn’t happy with how it was responding, so decided to try and fine tune it once and for all. :thumb_ups:
    The other not so good news is, when the bike was first registered, someone mucked up a digit of the VIN number and so I can’t register it yet! :headbang:

    Nearly there! :prankster:
     
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  19. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    Quick question:
    When measuring the fuel height of the carbs, is that done with the bike on a level surface and standing upright, and the carbs attached to the intakes as per normal use?
    (I read a post about setting up Mikuni carbs, and the FZR400 manual suggested putting a jack under the engine and setting the carbs vertically when measuring the fuel height.)
    53E9BFA6-36D3-4601-A196-EB143A742FA3.png
    I didn’t understand what that meant exactly and if it was relevant for the FZX250 too?
     
  20. Ben Jammin’

    Ben Jammin’ Member Premium Member Contributing Member

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    So, it’s been a busy few days.....
    The VIN number discrepancy turned out to be a typo by the RTA!
    The bike had been registered at different times with two different VIN numbers, 1 digit apart!
    However it is now registered with the correct VIN. :thumb_ups:
    Last time I updated, the bike was running, but still not great at all rev ranges. I checked the plugs and it was definitely running rich. No surprise there as I did have to wind the mixture screws out to 3.75turns!
    I did put the needle clips in the middle position.
    40F076BC-5DA7-43C4-A3F0-DEF73C3D4682.jpeg
    I had a look into the float heights, because I was measuring fuel height of -1mm from the line on the float bowl!
    What I found was that someone had bent the tabs on the floats slightly, presumably to try and weaken the mixtures??? Who knows?
    2836F9D7-CC37-4AFB-AFDB-AFA8ADB90442.jpeg
    I straightened the tabs, and the fuel height came up to just over 10mm above the line! Success!
    I started the bike and took the mixture screws back to the suggested 1.75 turns. There was a little hesitation up to qtr throttle, so I set the mixture screws out to 2.25 turns and all seemed to be much better.
    There was still a funny hesitation at around half throttle, so I thought sod it, and took the thing out for a blast.
    20mins later the bike was responding normally. Amazing! (I guess the goo that was stopping the inlet valve closing, needed a good blow out?)
    I took it home and removed the plugs and it still looked a tad rich. So I put the screws back in to 2 turns each and went for a long ride. The thing is running great! :crazypilot:
    I then treated it to a new oil filter and oil, and realised that I still hadn’t fitted my preload adjusters!
    So, I strung her up from the garage ceiling once more and proceeded to swap the fork caps for the adjuster caps. :dance2:
    73756E27-F184-4A05-A383-FFF2D4159732.jpeg 2E605133-6D08-4A89-AA1A-A4F37CC9B205.jpeg
    I can’t actually believe it’s done!
    There’s still quite a lot of tidying up to be done, but it’s actually running and on the road finally!

    Once again, thanks so much for all the help and support from you guys on the forum.
    I couldn’t have done it without you!
    :drinks:
     
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