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Help ZXR250C CARB PROBLEMS..

Discussion in 'Kawasaki 250cc In-line 4's' started by brodinatorr, May 29, 2015.

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  1. brodinatorr

    brodinatorr Active Member

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    *rebuilt* the carbs in my zxr250c today, new jets, needles, gaskets, everything.

    I installed everything, tank is full of 91octane, tried to turn on the bike with full choke and nothing for about 30 seconds, and on full choke the bike was revving at about 1,000rpm, and it sounded like it was running on 2 or 3 cylinders..
    Rev it and won't rev past 8,000rpm. What did I do wrong?

    I need answers since the zxr is my daily. Cheers.
     
    brodinatorr, May 29, 2015
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  2. kiffsta

    kiffsta Senior Member

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    What did you set your air fuel mix screws to ?
     
    kiffsta, May 29, 2015
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  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    When you first put the carbys back they need time for the float bowls to fill from empty

    Is the fuel tap on 'prime' ?

    Did u have the pilot screws out and replace the o ring and washer? ..... and if so what are they now set at?

    are the carb to airbox seals in place?

    Try to start it with no choke ... or half choke ..... and no throttle.
     
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    GreyImport, May 29, 2015
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  4. Phil

    Phil Senior Member Contributing Member

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    I would re-visit your air/fuel mixture settings, sounds like it may not be getting sufficient fuel.
     
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    Phil, May 29, 2015
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  5. brodinatorr

    brodinatorr Active Member

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    I will look at it again tomorrow. Ran out of day light today

    I am not sure what the air fuel mixture screws are, if you could upload a photo of what you mean that'd be great. I have no idea what each screw is called.. I am a newb at this. My first time I've seen the carbs in person, and I just replaced everything thinking it was okay...

    I am sorry if this isn't so clear guys.
     
    brodinatorr, May 29, 2015
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  6. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Each carb has its own idle circuit screw, sometimes called air screws. They control the air/fuel mixture for the idle circuit (throttle closed). If you have screwed them all the way in there will be no way you can start the bike. They need to be turned OUT a set number of turns as a starting point.

    Read Th3 Huntsman's guide

    http://2fiftycc.com/index.php?threa...in-your-zxr250-keihin-cvk30-carburetors.2651/

    The stock setting is 2.5 turns out. The red circles in the photo

    [​IMG]
     
    Linkin, May 29, 2015
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    No apologies required .... we all started from scratch at some point

    They should be turned in till u feel resistance (not tight) , then turned out to the stock starting position as posted above.
    360deg is 1 full turn

    Heres the pilot screw out of the carb

    Keihin pilot screw.jpg

    Position on each carb .. the 'external' screw above it is the float bowl drain screw

    mixture C.jpg
     
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    GreyImport, May 29, 2015
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  8. Phil

    Phil Senior Member Contributing Member

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    No problem mate, we'll try and get you going.
    @Linkin has just posted a photo for you and a link to work done by @Th3_Huntsman, feel certain both will assist with your problem. Each bike has different settings with the air/fuel mixtures so it pays to check what is applicable to your machine, you'll find this information in the manual for your bike.
    I have had issues with these on a Honda CBR250RR/MC22. The manual clearly stated 1 3/4 turns out which I set accordingly, however after draining my new battery many times changed the setting to 2 turns out and the bike starts every time without fail.
    Hope the info helps, keep us posted on your progress.
     
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    Phil, May 29, 2015
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Airbox to carb seal in place .....

    Carb seal.jpg
     
    GreyImport, May 29, 2015
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  10. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    Th3_Huntsman, May 29, 2015
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  11. brodinatorr

    brodinatorr Active Member

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    Thanks guys, the air mix screws didn't have springs, o-rings and the washer.. Oops

    Now my bike is revving at 6.5k... help me please boys :(
     
    brodinatorr, May 30, 2015
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  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Look for this ... its your idle adjustment knob

    idle knob.jpg
     
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    GreyImport, May 30, 2015
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  13. Th3_Huntsman

    Th3_Huntsman Senior Member Contributing Member

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    ^^^^ and possibly a vacuum leak
     
    Th3_Huntsman, May 30, 2015
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  14. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Make sure your carbs and airbox are seated correctly in their respective boots. Check any hoses that aren't fuel hoses for cracks or leaks.
     
    Linkin, May 30, 2015
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  15. brodinatorr

    brodinatorr Active Member

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    I know about the idle screw, once everything was bolted back down the throttle stuck, played with the idle screw.. nothing

    NOW a t-piece that must connects a in between 1&2 and 3&4 is broken, one of the ones that go to the front of the carbs when they're placed on the engine..
     
    brodinatorr, May 30, 2015
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  16. Phil

    Phil Senior Member Contributing Member

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    Is that a vacuum line ???
     
    Phil, May 30, 2015
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  17. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Photo please. Probably is vacuum line. Gaff/Duct tape may be a good temporary fix.
     
    Linkin, May 30, 2015
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  18. brodinatorr

    brodinatorr Active Member

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    The two lines connect to a smaller t piece which rubs a single line up into the front of the bike?
    I don't know how to upload photos but will get one tomorrow! Sorry guys
     
    brodinatorr, May 30, 2015
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  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    They are vacuum lines and it runs to the vacuum valve


    Carbs ZXR.jpg


    vacuum valve

    VV.JPG
     
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    GreyImport, May 30, 2015
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  20. brodinatorr

    brodinatorr Active Member

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    I figured out the problem, one of the cables that keeps the throttle shut(?) came out of the hole behind the starter block on the bars. I am sorry if I have confused anyone here ahah cheers for all your help.
     
    brodinatorr, May 31, 2015
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