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Pinned ZXR FUEL LEVELS (The real way)

Discussion in 'Kawasaki 250cc In-line 4's' started by sharky, Apr 22, 2018.

  1. sharky

    sharky Well-Known Member Premium Member

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    When it comes to setting fuel levels on a zxr 250, everyone just sets each float to roughly the same height-manual states 13mm +/-2mm, but why guess? Theres another method in the manual that actually measures your fuel level & should be done prior to adjusting any float heights. Screenshot_2018-03-03-18-56-57-1.png Screenshot_2018-03-03-18-57-41-1.png No one can use this method though, because you need Kawasaki's "special" fuel gauge, lets have a look at this guage Screenshot_2018-02-15-01-08-53.png Screenshot_2018-03-03-18-18-45-1.png Its nothing more than a tube with 10×1mm increments with 3 highlighted marks. The manual states 9.5mm +/-1mm from the mark,9.5mm being the total fuel range in the guage & the mark they refer too is the middle mark +/-1mm. Luckily for all theres a fuel guage in every chemist in the form of a 10ml syringe, a 2ml range in the syringe has all the markings needed over a 10mm long length. 20180303_174823.jpg Another problem doing fuel levels this way, there is only carb body #4 visible to measure off 20180421_162857.jpg This method makes it near impossible to measure fuel in carb #1 against carb body #4 mark unless it is horizontally perfectly level, ive had floats in a perfect gradient ie 12mm/12.5mm/13mm/13.5mm trying it that way. The best way is to seperate the carbs & mark each float bowl separately so that the fuel level can be measured against its own body. 20180421_142832.jpg 20180421_135748.jpg Another thing to consider will be supporting the carbs in a position so that the fuel mark is horizontal, but the carbs are stable & easy to work around. I use an old cd holder or even an old head. You will also need an auxiliary fuel can & 20cm clear hose 5mm I.d. 20180303_175011.jpg 20180421_110834.jpg TAKING THE MEASUREMENT Im using numbers 4-6 as my measuring range for this test so I must keep the 6 above the mark at all times. 20180303_180046.jpg This is how I hold the guage in place to free up my hands. 20180303_184030.jpg Now undo the drain screw a few turns, this is usually what happens, an air bubble, just pinch the hose at the fuel bowl end to bleed all the air out & wait till the fuel settles. 20180303_180209(0).jpg 20180303_180335.jpg Now lower the guage until the top mark (which is 6 in this case) is horizontal with the mark on the carb, making sure to never drop below the mark, a perfect reading would be 5 +/-1mm. 20180303_180520.jpg Its best to measure & record all 4 carbs before draining fuel & making adjustments, if the fuel height needs raising, raise the tang, lower fuel, lower the tang. Screenshot_2018-03-03-19-00-45-1.png Would of been nice if Kawasaki just said 5mm below the mark +/-1mm but hey, they charge 30$+ for that guage. You will have to wrap your syringe in clear tape also as the numbers are not fuel proof
     
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  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice work.
     
  3. Frankster

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

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  4. WiKaE

    WiKaE Member Premium Member

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    Lets say I wanted to pretend your excellent guide didn't exist and insist on measuring the float height instead.. Do any of you know which angle the carbs need to be at? Found an excellent youtube video that shows what I'm after:


    Haven't been able to spot a post about this except everyone repeating that the float height should be at 13+/-2 mm...
     
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  5. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    There is no angle. Just when the tang makes contact with the tip of the needle.
     
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  6. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I think as long as the line in the carby body casting is horizontal you should be right,
    if the carby sat at a different angle then Keihin would have had the line in the casting at a different angle to compensate

    zxr carb.jpg
     
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  7. sharky

    sharky Well-Known Member Premium Member

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    20190111_185922.jpg This is how the manual shows it done, no set angle, the needles need to be seated with as little weight from the floats on the spring as possible.
     
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  8. WiKaE

    WiKaE Member Premium Member

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    Thanks for the responses people! That should be all the info i need :)
     

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