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Help Kawasaki 1997 Balius running issues

Discussion in 'Kawasaki 250cc In-line 4's' started by Lemy, Dec 17, 2021.

  1. Lemy

    Lemy Active Member

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    Hi all,

    So I recently bought a balius as a project bike and I'm having some issues with it running right.

    It only wants to start on full choke and can only make it about halfchoke without stalling no matter how much I warm it up.
    Also when I go to rev when cold, often the revs drop and sometimes even stall. Also it doesn't seem to want to rev past 9k. Now the weird thing is, I took the carbs and apart and all the jets look in good nick, the float is approx correct height and the diaphram looks new. The idle control screw was as per the spec of the zx2r ( same engine sorta ) which is a full turn out from the balius spec which to me indicates it should be running rich but the requirement of choke indicates it's lean?!

    Petcock, fuel lines and filter all look...old, so I'll be replacing them, could there be any other explanation for why it's running so bad?

    Also my bike has 98 pilot jets on all 4 carbs, what spec is the pilot screw? I can't find that info anywhere.

    Thanks!
     
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    :welcome:

    I think u mean main jets and pilot jets :)

    balius carbs.png

    Check the setup on the pilot screw also

    PilotScrewAssy.jpg



    Fix the easy stuff first .... especially replace the inline fuel filter if there is one
    Theres internal tank filters also
    If u are talking old air filter , just run it with the air box and no filter temporarily

    Balius tank.png

    https://litetek.co/Carb_Kit_Kawasaki_ZR250_Balius.html

    Do this also ....

    https://2fiftycc.com/index.php?threads/trim-your-spark-leads.8032/

    https://2fiftycc.com/index.php?thre...eads-spark-plug-configuration-inline-4s.8176/

    A complete carby clean and rebuild is usually unavoidable
     
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    Last edited: Dec 17, 2021
  3. Lemy

    Lemy Active Member

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    Thanks for the swift and detailed response!

    Correct, my main jets are 98 all around instead of the 98 95 95 98 I've seen, that's where my confusion about the pilot screw comes from. I think I'll have to set it at 1 3/4 and fine tune once it's on.

    Planning on cleaning the tank woth vinegar tonight, would it be recommended to take the mesh filter out now or after?
    Inline filter and spark plugs are on the list before I put the bike back together.

    Thanks
     
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  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    If u need to keep the tank sealed while cleaning then just take it out when youre ready to "empty" it out .... tanks have a lip inside at the filler neck which will stop any crud washing out

    The small filters just press in so can be removed

    Internal filters.jpg

    Plugs are NGK CR9E
     
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  5. Lemy

    Lemy Active Member

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    Thanks for the help mate, I've only just got around to putting everything back together and I realised I've ****** up... I've completely forgotten where all the fuel lines and vac lines go as I thought I would've had this done last weekend.
    I have a basic understanding, but if anyone could advise where they'd most likely go that'd be very helpful, thanks!
    20211223_205530~2.jpg 20211223_205557~2.jpg 20211223_205136~2.jpg 20211223_205143~2.jpg 20211223_205415~2.jpg 20211223_205530~3.jpg
     
  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    The smaller line from the fuel tap is a vacuum line. It will go to one of the inlet manifolds. The large one is your fuel line.

    The nipple without a line on the tank is a drain hose, it'll goes down to the front sprocket area.

    The two outlets facing forward on the carbs are vent hoses. They either go to atmosphere (open with no hoses) or there should be some matching hoses in that area going to the fresh air valve if fitted (emissions device)
     
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    If the setup is same as the ZXR/ZX2R (Balius is the naked version) then the vent hoses run a single hose from this tee across the top of the airbox to an inlet there on top

    vents.png


    Red is fuel line from tap to carbs .... put in an inline filter

    Blue is your vacuum which goes to the other smaller pipe on the fuel tap as mentioned above

    hoses 2.jpg

    Im not familar with this but its the fuel sender unit and Im guessing that hose is just a vent as it has no sign of being clamped before ... ?

    20211223_205136_2.jpg

    And yes this is just a drain from under the fuel cap .... its a metal pipe that runs thru inside the tank .... they usually have a hose the outlets to ground under the bike

    20211223_205415_2.jpg
     
  8. Lemy

    Lemy Active Member

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    Thanks so much guys, it's really appreciated!

    I'll give it a crack tonight.

    Also from memory there's 1 nipple on the airbox and 1 vac line with a fresh air filter which to me doesn't really add up... Wondering if you happened to be able to make sense of this?

    Yet again, thanks alot!
     
  9. GeorgeT

    GeorgeT Active Member

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    Sounds to me like the carby bodies need to be ultrasonically cleaned. A bit strange though with a 4 carby bike unless all 4 carbies are contaminated by dirty fuel or something? I am assuming you put the carbies back together with the main jet needles in the same position you took them apart?
     
  10. Lemy

    Lemy Active Member

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    Hey mate,

    Turns out carb 4, the only 1 I didn't check was blocked... So i figure it was firing on 3 cylinders... I'll see how it goes once it's all back together.
     
  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    The hose setup with the mini filter is just a drain at the bottom of the airbox

    The Balius air box looks a little different on top to the ZXR but the red arrow looks like where the hose from the carb vents is attached

    airbox.jpg
     
  12. GeorgeT

    GeorgeT Active Member

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    Also check that there is no air leak on the engine boot connection side to the carbies, especially if you have a vacuum line for operating the fuel petcock. Any air leak will make the engine run lean exacerbating the "running on 3 cylinders" problem.
    Merry Christmas, stay safe. Cheers George.
     
  13. Lemy

    Lemy Active Member

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    Ahhh the joys of owning an old project. It started up first time, adjusted the throttle and idles perfectly without choke.
    The next morning I go to start it up and there's no response. No cranking, no clicking, no nothing. I've since noticed petrol on one of the leads to the starter relay. Could this have possibly shorted it out? I can't hear any clicking when I press the start button.

    Thanks!
     

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