Kawasaki ZZR help

[4skindiver]

Hi, im repairing a 1994 ZZR250 for a mate. It has not been run for 5 years. I replaced the battery as it would not charge. Drained the fuel from the tank and carbs (syphoned the tank and used the drain screws on the carbs) as it was stale. With a dose of fresh fuel it took a while to start but ran well.

However, after running for about 10 seconds, fuel poured onto the ground from a long clear hose by the rear shock. It looks like the hose fits to the rear of the carbs.

I took the tank off so i can inspect the carbs, but i cant get the air box out. there are 2 bolts on the airbpox under the battery, i have removed these, the airbox is free but wont fit through the frame. How do you take it out?

Also, im wondering why the fuel is being dumped. It also does this when you turn the fuel switch to "PRI" (not sure what PRI means)

Is this tube an overflow of some sort? I noticed that the LH carb was not draining fuel as well as the RH. Perhaps there is a float valve stuck or something?

help help please help!

[FilthyLuka]

Perhaps there is a float valve stuck or something?



that is a very good guess.

If its been sitting that long then gunk may have built up on the needle valve that closes the port effectively not letting it shut and overflowing the carbs.

Tear the carbs apart and give em a good cleaning

As for the airbox, IIRC the last zzr i worked on, they just lift out. addmitedly that was a 600 and not a 250.

If worse comes to worse, you could always cut the box out and put on some shiny pod filters :whistle:

Also it would've been a good idea to post this in the bike mechanics section of the forum

[breakaway]

Also, im wondering why the fuel is being dumped. It also does this when you turn the fuel switch to "PRI" (not sure what PRI means)!

PRI means prime, it's there to allow the fuel to freely flow in (it's for "priming" the carbs after you run dry).

[Dealer]

the air box wont pull out thru the frame. trust me, ive tried. if you want to take it out, you need to disassemble the seat frame, from memory 4 bolts. if you need a manual, i have the zzr250 supplementary on pdf, you would need to supply paper.

[Dealer]

this is what mine looked like as i put it back together

[4skindiver]

the air box wont pull out thru the frame. trust me, ive tried. if you want to take it out, you need to disassemble the seat frame, from memory 4 bolts. if you need a manual, i have the zzr250 supplementary on pdf, you would need to supply paper.

a pdf would be fantastic! new to the forum, how do i go about getting it from you?

before i go and disassemble the seat frame, is there anything major i need to know? (eg will the thing fall to pieces).

Thanks!

[Squiggles]

supplementary manual can be found all over the net, http://www.zzr-international.co.uk/forum/viewtopic.php?t=2905

i think thats the one you'll be after

the one that you really want though, is the ninja 250r base manual, i'll buy a digital copy tomorrow if i remember (have a bunch of stuff to ebay), and upload it somewhere when i do.

Supplementary shows a fair bit thats zzr specific, but engine wise, in all my searches of the net i could only get fiches and valve clearance tables for them