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89 ZXR250 Fueltap Failure.

Discussion in 'Kawasaki 250cc In-line 4's' started by InvaderIMD, Oct 8, 2016.

  1. InvaderIMD

    InvaderIMD Active Member

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    Hey all.

    Back again with another Problem and Question.

    Just helped my partner buy a new upgrade from his cfmoto.

    Bike was from what i can see an ex-track bike(had lots of stickers) but looks good, back tire is running low, but went for the second ride today and the bike started pissing out fuel...Slowing down form 80...not good.
    here is where it broke... DSC_1527.JPG
    The service manual does not state that these parts can separate.

    Here is a video of what happened.

    My question,
    Does any one know how to fix or somewhere we can get a new one?.....Or one that works from a different model?
     
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  2. Adam Giles

    Adam Giles Well-Known Member

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    There were new ones on eBay, not cheap though.

    Sent from my HTC Desire 620 using Tapatalk
     
  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    My Yamaha had the same part come loose, i just bought some Devcon epoxy, mixed it up and smeared a little on the tube that came out and tapped them back together, then smeared a little more around the join on the outside, and left it overnight to set.
    It's been fine ever since

    Devcon or JB Weld can be bought at most good car part's place's like Repco, Autobarn etc, Permatex also have a similar product-
    http://www.supercheapauto.com.au/Product/Permatex-Cold-Weld-Bonding-Compound-57g/129919
     
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  4. InvaderIMD

    InvaderIMD Active Member

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    Thanks ill try that tomorrow.
     
  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Just go easy with the epoxy, you won't need much at all, mix up a little to just cover a 5c piece
    It set's rock hard
     
  6. tarmacsurfer

    tarmacsurfer Well-Known Member

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    ZZR250 tap is the same. There's a lot around on eBay.
     
  7. Rossco_Perth

    Rossco_Perth Confirmed Tinkerer :)

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    I had this same issue.

    A simple fix it to use Loctite red (high strength) thread lock, it sets in the absence of air (anerobic) and is fuel proof.

    saves using epoxy which petrol/ethanol will eat over time.
     
  8. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    We use Devon to help shape inlet port's on race engine's, never had a problem with it in the last 20 year's
    I reckon it'd be fixed a long time ago now anyway, this was october last year
     
  9. Rossco_Perth

    Rossco_Perth Confirmed Tinkerer :)

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    Yeah, I've used Devcon to seal water jackets on my peripheral ported rotaries too... It's a great product but it doesn't like to be immersed in fuel long term.

    Most people have loctite in their toolbox but aren't aware that it sets in fuel & will seal press fit fittings.

    I just added this info here for others that go searching for a fix

    Sent from my iPhone using Tapatalk
     
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  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Dunno i have never used Loctite 515.
    But i did fix my fuel tap with Devcon almost 12 month's ago, and a couple of other's long before that
    Same thing with Holley fuel bowl's.
     
  11. Rossco_Perth

    Rossco_Perth Confirmed Tinkerer :)

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    Like I said I just added the info as an FYI.

    Might just help someone stuck on the side of the road when that press fitted elbow falls out mid-ride.

    Have been in the auto industry for 25+ years too


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