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Pinned How to Clean Your Carbies on a Kawasaki ZXR250C

Discussion in 'Kawasaki 250cc In-line 4's' started by kiffsta, Mar 6, 2012.

  1. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    OKay, I have a spare set of ZXR carbies, so here is a quick run down for clean ing a set of 4 Keihin CVK D30's off a ZXR250C

    The manual for the carbies is here
    https://2fiftycc.com/index.php?resources/zxr250c-fuel-system.97/

    Steps

    1. Remove your rider seat
    2. Remove your tank by undoing the bolts, when you lift the tank, you need to under the fuel hose to the petcock.
    3. Remove lower fairings from your bike
    4. Undo air box lid 2 x 12 mm chrome bolts on top and the bolts on the side of the airbox.
    5. Remove Air cleaner
    6. Remove the 8 gold bolts that go into the carby, they wont undo all the way as the plastic in the airbox stops them coming out easily.
    7. Remove lower airbox assembly. Its really important to keep an eye on your carby gaskets as they may stay on the carby or be stuck to the airbox, dont break them, they are really expensive to replace.
    8. Use a torch and look at the lower side of the carby ( between the engine and the carby) under the frame and you will see a philips head screw protruding from each carby, you need to undo these on each carby about 3 - 4 turns to loosen the carby from the manifold,
    9. Once all 4 are undone, you can rock the carby back and forward to release them from the manifold.
    10. remove the throttle cables and choke cable and your ready to clean the carbies.

    This isn't the hardest job, but if your not sure, then go so your mechanic, they charge $90 an hour and will a better job than you :)

    1. Once the carbies are out, drain the fuel by turning them side to side.
    2. set yourself up in a clean work area, you should have some plastic tubs to put all the parts in so you dont loose them.
    3. Remove the 4 screws holding the float bowl on and set aside.
    4. Clean all junk from the float bowl.
    5. Use a 8mm socket or spanner, remove the main jet holder and the main jet
    6. Using a flat bladed screw driver, remove the pilot jet
    7. Undo the philips head screw holding the float bar on and remove the float
    8.The needle will come out with the float, undo the philips head sear the seat and use a set of pliers to pull the brass seat out, there is a filter under there.
    9. Remove the main jet using a flat bladed screw driver from the the main jet holder\ emulsion tubes
    10. OKay, now to clean them, using some carby cleaner, ensure all junk is removed from the float bowls and set aside.
    11. Inspect your main jet, hold it up to the light , you should have a small hole there, if not, clean with carby cleaner to remove the blockage.
    12. The main jet holder is hollow, but you cant see through it, just ensure all the small holes on the side of the tube are clean and not blocked, ensure each end is also cleaned, then set these aside.
    13. Inspect the pilot jet, use carby cleaner to remove any junk and hold up to the light, there should be a very small hole ( much smaller than your main jet), remove any junk then set aside.
    14. Remove your needle from the floats and ensure the little plunger at the end will depress down if pushed, use carby cleaner and ensure its clean, set aside with other parts.
    15. Inspect the seat and use carby cleaner to remove any junk from the filter, set aside with other parts.
    16. Use some carby cleaner to clean out the rest of the carby before re-assembly.
    17.Now the carbies are apart, lets re-assemble, refit the seat\ filter and secure with the phillips head screw.
    18. Insert pilot jet and tighten using a flat bladed screw driver
    19. Insert main jet into main jet holder and insert into carby, tighten using an 8mm socket, then tighten the jet into the jet holder.
    20. Feed the float valve needle on to the float and slide into the "seat"then ensure the slide bar is in place and do up the phillips head screw to hold it in place. Gently push down on the float bowl and it springd back to you. Measure the float bowl height to ensure its at 13mm ( + or - 2mm)
    21. reattach the float bowl, check for anything yu ahve forgotten, all parts should have gone back in.
    22. Flip carbies over and under the 4 screws on top the carbies, be careful as there is a long spring under there that will try and pop
    out.
    23 Remove the spring and set aside with other parts.
    Remove the diaphram and inspect for tears.
    24. Inspect the Jet needle and ensure its not bent and ensure its clean and free of any dried fuel (varnish).
    25.clean the top of the throttle body with carby cleaner including the diaphram, needle jet and top cover.
    26. Slide the needle jet into the diaphram and slide the diaphram back into the carby body, be careful to ensure the needle goes down the brass hole at the bottom.
    27. Refit plast brace to the spring and slide into the diaphram.
    28. Reattach the top plate using the 4 screws provided, ensure that the spring goes into the holder in the plate or you will damage your spring.
    29. Repeat on the other 3 carbies and you should be sweet.
    30. Have a beer or cold beverage to celebrate a job well done.


    You will notice I didnt remove the air \ fuel mixture screws, you can, but you will need to balance the carbies once the bike is back togther and running. If you do this, watch out for the little rubber and metal washers and springs.

    Just refit your cables to your carbies, then I spray some WD40 on the carby manifold to help ease the carbies back in, they arnt easy but will go in. Reassemble your bike, prime your carbs all going well they will run well.

    Disclaimer - fortune favours the brave, but get this worng and you could damage your engine if your carbies are incorrectly set. Your motorcycle mechanic will charge $90 an hour and will do this for you, could be up to a 3 hour job for all 4 carbies :)

    Have fun

    Chris






    Tips
    1. Do I carby at a time only.
    2. Do not loose or break your carby airbox gasket
    3. stock jetting is 122's on the 2 outer carbs and 125's on the middle
    3. Dont force it
    4. Float height is 13 + or - 2mm
    5. Pilot screws \ Air Fuel mix is 2.5 turns out + - 1/4 turn

    IMG_2192.jpg IMG_2193.jpg IMG_2194.jpg IMG_2195.jpg IMG_2196.jpg IMG_2197.jpg IMG_2198.jpg IMG_2199.jpg IMG_2202.jpg IMG_2203.jpg
     
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    Last edited: Nov 15, 2016
  2. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    couple more pics

    IMG_2204.jpg IMG_2208.jpg IMG_2209.jpg
     
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    Last edited: Nov 15, 2016
  3. Slender

    Slender Well-Known Member Premium Member

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    Nice write up Kiffsta.
    It's time consuming but relatively easy.
     
  4. zxr250

    zxr250 New Member

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    kiffsta - you're a champion!

    Great write up and very thorough instructions. Thanks for taking the time to do that.

    re: the carbie's - its missing a few screws and a couple of those little white things that look like miniature horns, but the bike still runs well. I'd love to replace the missing screws though - do i need to get these custom ordered or do you think i could just get bunnings to match the screw size?
     
  5. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    No worries, actually took heaps longer than I thought it would :) I so have a spare set of ZXR250 carbies in bits, send me pics of what screws your missing and I can post them to you for a small fee chris@2fiftycc.com .  The horns are not important , dont stress about them.
     
  6. zxr250

    zxr250 New Member

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    Much appreciated kiffsta!

    I'll open up the bike again and let you know whats missing.

    Thanks alot mate.
     
  7. drat

    drat New Member Premium Member

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    thanks mate was wounderin how to remove seats was gonna try with pliers just didnt want to damage them and has any one clipped their springs and drilled extra hole in slides, the jet kit i got mentions it but says it way altour low rev riding not that its at low revs often great post heaps detailed
     
  8. Artemis

    Artemis Well-Known Member Premium Member

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    The zxr has 4 carbies...? Wow.
     
  9. pickels87

    pickels87 New Member

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    Hey Chris,
    Mate those instructions worked great thanks for the help you made my job a little easier.
    Cheers Chris  :occasion14:
     
  10. Phil

    Phil Senior Member Premium Member Contributing Member

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    Hey Chris

    Great write up on the carbs coupled with excellent pictures, sure it will be greatly appreciated by many. Good job.
     
  11. kds1

    kds1 Active Member Contributing Member

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    awsom Chris will do mine on the weekend good stuff
     
  12. alex

    alex Member

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    Since we are on the topic of carbbies anyone know where i could find screws that would replace the existing ones which connect the float bowl to the carbbie? I know you need those special screwdrivers and mine have been opened with phillips head one too many times in the past.
     
  13. Phil

    Phil Senior Member Premium Member Contributing Member

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    Hey Alex
    1) go to your nearest Kawasaki dealer, they should be able to help.
    2) Nut and bolt shop, they may help.
    3) Check online for carb shops.
     
  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  15. kds1

    kds1 Active Member Contributing Member

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    I have been going to nubco or nuts and bolts hear in tas just take in the ones you have and thay will match length thred and material and it`s Cheaper i have replaced water pump bolts carbi screws and all my fairing bolts also you can get alan head bolts insted of philips head good luck keep us posted
     
  16. kds1

    kds1 Active Member Contributing Member

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    Yep greys right dont tell them it`s a zxr
     
  17. alex

    alex Member

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    Cheers guys....you are awsome
     
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  18. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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    Hi Chris/All,

    Me again. Just started rebuilding a set of ZXR carbs that I bought on eBay. New to this so snicker quietly please...

    In the manual it mentions the pilot jet should be 2.5 turns out. My questions are...

    1. What affect does changing the number of turns have on the engine e.g. going to 2 versus going to 3?
    2. Should the number of turns also apply to the Air/Fuel mixture as well?
    3. What is the relationship between the pilot jet and the air/fuel mixture? Is there one?

    Thanks again folks

    Frank
     
  19. Russky

    Russky Careful, man, there's a beverage here! Premium Member Contributing Member

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    Hey mate. Im brand new to the zxr too, but from what ive learnt cleaning out my carbs, where the manual talks of the pilot jet, what they actually mean is the fuel/air screw. the pilot is screwed down all the way, and is not adjustable, as on some bikes.

    By the way, great writeup Kiffsta, would i have come across this before i stripped mine down lol
     
  20. Frankster

    Frankster See the World before you leave it Staff Member Premium Member Ride and Events Crew

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