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Help ZXR250 idle issues... (another one)

Discussion in 'Kawasaki 250cc In-line 4's' started by DanoHosko, Dec 7, 2019.

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  1. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Not a gap filler ?? .... o rings are used to seal fuel,water, oil and wateva else in a zillion situations but they wont seal a bit of air thats not even under pressure?? :lolsign:

    :commando:


    Also note that if they are the correct set they will more than likely be numbered for each cylinder .... cylinder 1-4 is left to right
     
    Last edited: Apr 15, 2020
    GreyImport, Apr 15, 2020
    #41
  2. jmw76

    jmw76 Well-Known Member

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    Clarification, if the o rings are compressed or damaged at all they will not seal well. Yes, used in thousands of applications, but they still can leak. -15psi (vacuum) in the manifold. So, yes they are under pressure. Air is a lot less viscous than water and oil so even small leaks can be quite significant. You do not need much of a leak to upset the idle characteristics of your engine.
     
    jmw76, Apr 15, 2020
    #42
  3. TonyZXR

    TonyZXR Well-Known Member

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    Also something to add that i havent seen mentioned yet is check the condition the clamps, they do stretch from being tightened and loosened , even with new manifolds it'll still suck in air if the clamps dont tighten hard enough

    Sent from my SM-N960F using Tapatalk
     
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    TonyZXR, Apr 15, 2020
    #43
  4. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    I'll be honest, im leaning towards just biting the bullet and getting new ones so i can rule it out

    Good point i didnt even think about the clamps either

    Part number is 92170-1094, local Kawasaki says "part not found' on their system apparently
     
    Last edited: Apr 15, 2020
    DanoHosko, Apr 15, 2020
    #44
  5. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ok today im attempting to sync the carbs, so far having big headaches and i imagine the neighbour's aren't happy either....

    At one point cycl 3 was pulling more than the others but the idle was probably the best it ever been, tried to adjust but when 3 stopped pulling so hard the idle went sky high again

    Im probably going to re-bench sync again then try this sync with the makeshift manometer, think ive probably messed it too far now
     
    DanoHosko, Apr 25, 2020
    #45
  6. maelstrom

    maelstrom LiteTek Premium Member 250cc Vendor Contributing Member

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    Buy a Morgan Carbtune, my two cents.
     
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    maelstrom, Apr 25, 2020
    #46
  7. Linkin

    Linkin The Mechanic - Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    I'd suggest the threebond engine conditioner treatment and then re-attempting the balance job. Mixture screw setting is important, to find each cylinders happy place and then do the balance... If the balance reads good and the idle goes high that's good, adjust your idle down and enjoy a smoother running, more powerful, more fuel efficient ride.
     
    Linkin, Apr 25, 2020
    #47
  8. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    I would like to but damn im getting reluctant to buy more tools at the moment, i imagine it could be a few weeks wait for one to be delivered at the moment too, might bite the bullet yet


    I'll be honest, not sure how to get the mixtures right per carb without getting it idling ok, seems like i need the mixture and the sync right but not sure how i know which is the true problem

    I set them all to 2 1/2 turns after rebuild
     
    DanoHosko, Apr 25, 2020
    #48
  9. TonyZXR

    TonyZXR Well-Known Member

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    Doesn't help that the mixture screws are in such a **** spot, very specific screwdriver is needed. +1 for the morgan carbtune , such a good tool
     
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    TonyZXR, Apr 25, 2020
    #49
  10. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Ok sweet, im happy, starts first time, idles at 2k, carbs seem to be synced with each other,
    Good enough to get the roadworthy anyway


    Few things to take away from today:
    - Good bench sync is a must
    - the tiniest adjustment is required when syncing with the manometer to make a change
    - i have adjusted the mixture out a little


    :party:



     
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    Last edited: Apr 25, 2020
    DanoHosko, Apr 25, 2020
    #50
  11. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Sorry guys, im stuck again

    Bike has decided not to start at all today
    Turns over and i have spark to the coils (havent checked the spark plugs themselves as i used a spare to test but the others should be near new)

    Shouldn't be any changes to the airlines or vacuum lines

    The fuel tank wasnt installed so i connected up and set fuel tap to prime for probably 5-10 mins

    Battery measures 12.7V after a fair few starts this dropped to around 12.5V

    Is there a trick to priming them?
    Is the battery knackered?


    I very nearly threw my toys out the pram...
     
    DanoHosko, Apr 27, 2020
    #51
  12. TonyZXR

    TonyZXR Well-Known Member

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    Should just be fuel tap on prime for 30 secs then switch to on , choke on full , no throttle should start straight away.

    Sent from my SM-N960F using Tapatalk
     
    TonyZXR, Apr 27, 2020
    #52
  13. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Over the weekend i reassembled and it was starting perfectly, no throttle and without choke still started
    Today after fixing the headlights its playing up haha

    Maybe the coil leads are funked but giving a weak spark?
     
    DanoHosko, Apr 27, 2020
    #53
  14. TonyZXR

    TonyZXR Well-Known Member

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    Doubt it, usually just causes missfires but wouldn't hurt to replace them. If it starts without choke you have the pilots a bit too rich.

    Sent from my SM-N960F using Tapatalk
     
    TonyZXR, Apr 27, 2020
    #54
  15. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    I'm still skeptical of replacing electrical things as it was literally perfect yesterday, only things thats really changed is i fixed up the headlights to work and put the fuel tank on (had been using an old coke bottle with fuel)
    Fuel tank lid is open

    I wouldn't rule out the battery as it has had a bit of a hammering this weekend but i stuck it on charge overnight
     
    DanoHosko, Apr 27, 2020
    #55
  16. TonyZXR

    TonyZXR Well-Known Member

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    Does the fuel tap let fuel flow through on prime?

    Sent from my SM-N960F using Tapatalk
     
    TonyZXR, Apr 27, 2020
    #56
  17. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Yeah bud, free flows on prime
     
    DanoHosko, Apr 27, 2020
    #57
  18. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    I'll stick the car battery on her tomorrow so i can rule out battery issues if it still struggles
     
    DanoHosko, Apr 27, 2020
    #58
  19. ShaneP

    ShaneP Well-Known Member

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    Welcome to the wonderful world of carbies. If the plugs are wet (fuel) then it won't start. Pull out the plug (at least one) and check it out. These carbies overflow into the intake of the motor rather than onto the ground. If the plug is wet, crank it over while the plugs are out - be careful not to set the bike on fire. Also, how's the fuel in the tank? Fresh? Clean, no water? Vacuum line on? Tap diaphragm not leaking?
     
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    ShaneP, Apr 29, 2020
    #59
  20. DanoHosko

    DanoHosko Well-Known Member Premium Member

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    Haha wonderful indeed
    Ok so to update, found the plugs were soaking and fouled yesterday night, cleaned them up and got it to fire up for a few seconds
    You are bang on, engine seemed to be flooded with fuel, probably my fault leaving it on prime for like 10 minutes and cranking it over how ever many times...

    HT leads are worse for wear, found the rubbers damaged (jolt to the hand) on one so possibly arcing inside the plug hole rather than getting to the plug itself

    Fuel tap is new, albiet chinese it works fine and fuel is fresh

    I think theres a combination of things:

    - Battery is pretty lousy
    - fouled plugs not sparking
    - engine flooded
    - ht leads and caps are on their last legs


    Main thing is she did fire up briefly before the battery dropped to 12.4V, so CDI isn't cooked which i was concerned about haha
     
    DanoHosko, Apr 29, 2020
    #60
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