ZZR Help

[4skindiver]

Hi, I posted this in the wrong area, so ill give it a go here. got some great advice, but i believe you guys are the best option!

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 ok.

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!

[dino3310]

dont know the zzr,but the pri... is for prime,if im right there is a ON , RES ,
PRI on the fuel tap,prime is just for flushing fuel through the on and reserve work of a vacum

[Max Preload]

The reason the fuel is pissing out is likely a stuck float valve... and given it's been sitting so long that becomes even more likely.

[4skindiver]

So is there an easy way to take the carbs of this model, considering the airbox is too big to simply pull through the frame?

Me thinks me should have been a gynacologist

[skidMark]

The reason the fuel is pissing out is likely a stuck float valve... and given it's been sitting so long that becomes even more likely.

either stuck float valve or crap in it.

you do not need to take the airbox fully out on the zzr just leave it in...trust me ive been there with a gpx....essentially a zzr....

pull carbys off and pull the bowl off...

be very careful not to strip the screws....

very easy to do....

if you do ...jut drill the heads off and replace them....

once the bowl is off you can get to about 5mm of the bolts so easy to get out with pliers.

anyways ...prob stuck valve...if you are worried about it take it to a mechanic...

at the end of the day.....

bikes are simple....people go on to me wow you do the work on your bike...

i mean damn...it's just bolts!


you undo...and do em up...take it aparts...put it back the same way....aint hard.

rant over...hope sumthing in the babbling helps.

[Mully]

either stuck float valve or crap in it.

How often should he be crapping in it??

[skidMark]

How often should he be crapping in it??

depends...if it's a honda it's self crapping.

[Doogle]

Before going to that effort you may want to run some carbclean throught the carbs and gently tap the side of the carbs with a wooden mallet.
It might save you a bit of effort of they aren't seriously gunged up.

[Squiggles]

Before going to that effort you may want to run some carbclean throught the carbs

But not on the rubber parts (diaphragm in particular)

Why do you want to take the airbox out? You just undo any screw clips, and remove any other spring ones that hold the carbs to the intake manifolds & airbox and then jiggle them back from the intake and up till they come out

I found i had to use a hair dryer to warm up the rubbers to make them pliable enough to reseat properly when i did it to the mrs' zzr