New guy here, looking for help.

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14 Jan 2012 11:32 #498035 by VdubbPeach
New guy here, looking for help. was created by VdubbPeach
Hey guys, I have been a BMW tech for while now and work on VW's for fun but I have never really had a reason to mess with carburetors before, so they are new to me. I have recently accuired a 78 kz650 SR that was my fathers. It has been sitting in a storage bin under a tarp for somewhere around 5-6 years.
I took the carbs off and cleaned/freed the floats and needles but 2 of them still over flow. (the 2 that were the cleanest?) So my question is, if the floats/needles are free, then where else do I look to solve the over flow situation?

Motorcycle Newbie
1978 KZ650 SR

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14 Jan 2012 11:55 - 14 Jan 2012 11:55 #498038 by 650ed
Replied by 650ed on topic New guy here, looking for help.
You should be able to clean the float needle and orifice with a Q-tip and carb cleaner (do not use anything abrasive!) so they mate together and don't leak. If you can't get them to stop leaking they may be damaged, so you may want to replace them. Also, if you mixed the parts up between the carbs (a no-no), you may not have a matched pair. If this is the case, try switching the float needles between the 2 carbs that leak to see if that helps. If you need to replace them the good news is that they are still available from Kawasaki, so any dealer can get them. Assuming you have the original carbs; they are part number 16030-1001 "Float Valave Assembly." They come as a matched set of needle and orifice, so don't mix them up. Ronayers.com lists them at $25.43 per set. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Last edit: 14 Jan 2012 11:55 by 650ed.

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14 Jan 2012 12:00 #498040 by 650ed
Replied by 650ed on topic New guy here, looking for help.
Another possibility is that you installed the floats upside down, or accidentally bent the float tangs so the float valves never close. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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14 Jan 2012 12:15 #498041 by Patton
Replied by Patton on topic New guy here, looking for help.
Hello, VdubbPeach, and WELCOME to KZr! :cheer:

Some of the possible causes for gasoline discharge from overflow would include:
Imperfect fit of float needle into seat orifice;
Crud or grit at float needle interface with seat orifice;
Worn pointed tip of float needle;
Failure during re-assembly to keep same float needle with its same seat;
Incorrect float height adjustment (tang setting);
Float bent or rubbing against bowl;
Float installed upside down;
Float leaking;
Cracked overflow tube (often repairable).

Good Fortune! :)

1973 Z1
KZ900 LTD
The following user(s) said Thank You: VdubbPeach

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14 Jan 2012 12:33 #498043 by VdubbPeach
Replied by VdubbPeach on topic New guy here, looking for help.
Thank you for the warm welcome! I was glad to see a specific fourm for these bikes and all the activity of the fourm.

I was very careful not to flip parts or switch parts between carbs. Sounds like my problem is either the needle being worn or something such as grit is stoping it from closing off. looks like they are coming back apart today! B) thanks for the help guys.

Motorcycle Newbie
1978 KZ650 SR

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14 Jan 2012 12:43 - 19 Feb 2013 13:18 #498047 by martin_csr
Replied by martin_csr on topic -
.
Last edit: 19 Feb 2013 13:18 by martin_csr.

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14 Jan 2012 14:20 - 14 Jan 2012 14:27 #498062 by Patton
Replied by Patton on topic New guy here, looking for help.
For seemingly inexplicable reasons, a freshly re-assembled carb may initially discharge through the overflow circuit, even when supplied with fresh gasoline passing through a good aftermarket inline fuel filter.

With engine at idle rpm, and fuel discharging from an overflow nipple/hose, the discharge may often be eliminated by rapping smartly and repeatedly against the side of the float bowl with a plastic mallet or large screw driver handle. Usually takes less than a dozen raps.

Am not quite sure why this works, but has often worked for me, and should be worth a try. And would do this before again disassembling the carbs for further cleaning efforts.

If the overflow tube is cracked or loose at its connection inside the bowl, any crack may be very fine and difficult to notice. Such tube leakage may be readily tested with float bowl removed from the carb and filled to the brim of the overflow tube.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 14 Jan 2012 14:27 by Patton.

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