rosszx9r

well i guess if i've got a moped or a scooter then this is the place to be otherwise, i need to find a motorbike forum.......

Hi Guys, long time no speak bike has been off the raod since last summer when i blew the head gasket! finally got round to rebuilding the engine... (ZX9r B1 44k miles) making progress with the engine rebuild.... top end complete with no issues but i'm baffled with the gearbox fault... the reason i was stripping the bottom end was because the bike was not always engaging 2nd or 3rd gear from time to time unless i really forced it through. it would also occationally jump out of gear when under load. i was expecting to see worn forks or dogs but they all seem fine... http://www.postimage.org/image.php?v=PqEiuNr the fork ends measure 6mm which acording to the haynes, it spot on. the fork ends do look shiny and at first i thought they had been rubbing but this is just coloration. i can't feel any signs of actual wear (there would be a step from light to dark areas) any suggestions on what else it could be? (selector drum is fine too) all help appreciated.

kwakers use the cooling system to stop the carbs icing up. twas just an idea before knowing what bike it was i'd suggest you drain the fuel tank down completely and refill with fresh petrol.

i'd be very surprized to find it is water! are you sure it's water? do you turn the fuel tap off at night? if the float valve in carb isn't seating properly and you leave the fuel tap on, you'll over fill the carbs so draining them down would allow the bike to run properly. this is just a guess but far more likely than water building up in the carb after a day or so. if it really is water then it could be from the cooling system. what bike is it and how old is it

how long have you had it? more than a couple of months and you don't really have any come back on the shop. sounds like they can't @rsed to sort it for some reason! if you bought it recently from them, you really need to push them to sort it quickly or you'll loose your oppertunity. don't be too sypathetic toward them, they may well of knowingly sold you and old dog of a bike!!! there are loads of things you could check on the bike but it depends how much you can do yourself.... plugs, ignition lead condition, fuel/ air filters, oil levels, battery charging, good earth connection......... have you tried calling a dealer to get an idea of prices? it may not be as bad you think and they will certainly be able to sort it out.

most common fault is excessive use of the throttle enjoy...

first thing i'd check is the throttle cables. you have one to open the throttle and one to close it. if the closing cable is broken then only gravity can close the throttle!

OOooooooooo........ got your toys back yet?

NO NO NO NO NO... if he doesn't know what went where, then stripping it down to the sum of its parts means he has a pile of bits and no idea where to put them.. gives us some amusement though......

kawasaki carbs have a vacum diaphram on the top of them to open the main throttle body inside it. what you describe could be any one of the following... vacum hose split diaphram split or leaking badly carb sliders stuck or a very stretchy throttle cable take the tank and airbox off and check all the operating cables work (i.e. the butterfly valves open on the carbs) check the hoses (again just in case) then with throttle open (engine off!) stick your finger inside each carb and slide the throttle body up then let it drop back down. each one should be perfectly smooth with no sticky points and should make a swooshing sound when pushed up as air escapes from above the carb body. if not, it's a full carb strip and examination...

i'd check to make sure the fuel tap works and that any inline fuel filter is clean. then look at cable/pipe routing. something is clearly being dislodged or trapped when you put the tank back on. it may not be the tank thats trapping something, it could be pushing part of the airbox down onto something.

just a thought...... there is a small drain screw in the bottom of the carb that has a small hose attached to it.... the drain screw is closed isn't it

so take it back and get it fixed

if it's leaking fuel when not running, its the float valve that is not seating correctly. usually stripping down and cleaning is enough but it may be worn. wemoto do replacement kits for around £10 to find it: take the bottom off the carb, the float has a little flange that presses against a spring laoded plunger (bery small, about 1mm in diameter). remove the hinge pin from the float. this is sometimes held in place with a small screw at one end of the pin. once the float is removed, the float valve can be lifted free and cleaned. once clean, you will need to reassemeble and set the float to the correct hieght. this can be very model specific so you'll need either a haynes or a helpful kawasaki dealer to give you the clearance figure. you've done the hard part by taking the carbs out

i wouldn't laugh mate, if your getting gas in the coolant, the head gasket may of popped exact same symptoms as my deceased ZX9...