Connecting Fuel Tank Kawasaki GPX

[berry1]

Hi guys

Some of you may remember the Kawasaki GPX 600 that i was fixing up was a few months ago so probably not. I picked the bike up cheap and it wouldn't start so ive changed the spark plugs - new battery and the main 30amp fuse and now the bike is turning over really ncely great news as ive been trying to get this thing fixed up for a while it just unfortunately been slow to sort out as i was busy with other projects.

Now all i got to do is reconnect the fuel tank and it should be good to go now this is posing a small issue for me as i wasn't the one who disconnected the fuel tank in the first place.

This is going to sound dumb but i got to ask as im stumped on this and dont want to connect them in the wrong places but i got 3 pipes that need connecting and i have NO idea whatsoever where they connect to. 1 or 2 of them should connect to the fuel tank i think maby all 3 but im unsure and the last thing i want to do is connect the pipes in the wrong places.

Ive posted some pics bellow of the 3 pipes and labelled each pipe in the photos as A - B and C if someone could help me with this i would appreciate it

A

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0914_zpsb398d7db.jpg

B and C

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0916_zps1d7745aa.jpg

[Tango]

I would guess that the 2 pipes go onto that T-piece.....assuming that the pipes come from the fuel tap....one for main tank and the other for reserve....and the other pipe on the T-piece I assume is going to the carbs?.....

[berry1]

I would guess that the 2 pipes go onto that T-piece.....assuming that the pipes come from the fuel tap....one for main tank and the other for reserve....and the other pipe on the T-piece I assume is going to the carbs?.....

 

Thanks for the reply tango im still confused though as the other 2 pipes are not coming from the fuel tap. Right now i got 1 pipe coming from the fuel tank - 2 pipes coming from out the bike and another pipe which is the T piece that is located near the battery.

Heres a picture of the bike and where the 2 pipes are coming from and the T piece Ive labelled each pipe A - B and C

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0918_zpsddcc0c4c.jpg

Under the fuel tank there is a thing i think this is the fuel tap? picture bellow

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0922_zps548d119f.jpg

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0921_zps626aff79.jpg

Located at the back of the fuel tank is another small pipe coming out of the petrol tank i have no idea what connects to this either

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0919_zps3585f923.jpg

I also got another pipe coming directly out of the fuel tank ?

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0923_zps9773b20d.jpg

So 2 pipes coming out of the bike plus a T piece coming out of the bike near the battery and another pipe coming directly out of the fuel tank.

[eastanglianbiker]

the larger bore hose with the filter in line will go to the bigger hose outlet on fuel tapthe other hose with it is likely to be the vaccum for the tap and goes to outlet on base of tap hose coming out of the bottom of the tank is very possibly tank breaher and just needs to be left loose but i might be wrong on that one but fuel tap definatly needs 2 hoses test which one is vacum pipe by turning engine over on starter and see which hose is sucking air in using ur finger

[berry1]

the larger bore hose with the filter in line will go to the bigger hose outlet on fuel tapthe other hose with it is likely to be the vaccum for the tap and goes to outlet on base of tap hose coming out of the bottom of the tank is very possibly tank breaher and just needs to be left loose but i might be wrong on that one but fuel tap definatly needs 2 hoses test which one is vacum pipe by turning engine over on starter and see which hose is sucking air in using ur finger

 

Thanks for the advice man i turned the engine over to see which pipe was sucking air and you was spot on it was the smaller pipe that was sucking in air. I connected the smaller pipe to the outlet on the base of the fuel tap and the larger hose i connected to the side outlet of the tap. I then put the tank on and connected the electrical connection to the bike.

I tried firing the bike up and it turns over really loudly so the battery is for sure all good but when i pull the clutch and press the start button the bike does not turn over and makes no noise whatsoever! if i dont pull the clutch and press the start button it turns over no problem but with the clutch pulled it wont turn over.

Just to point out i never connected the T pipe to anything and theres a small outlet at the back of the fuel tank that was connected to nothing.

If anyone has any idea on this would be great thanks!

[berry1]

Even not pulling the clutch and with the fuel tap turned on it wont start

[stumblebum]

Click on the correct year here: http://www.cmsnl.com/kawasaki-zx600_model12816/

I believe the zx600 is the same bike as your gpx, I hope the diagrams are of some use to you!

[berry1]

Click on the correct year here: http://www.cmsnl.com/kawasaki-zx600_model12816/

I believe the zx600 is the same bike as your gpx, I hope the diagrams are of some use to you!

 

Real big help thanks so now i got the pipes connected right my only other issue is that i still cant get the damn bike to start. Sprayed starting fluid down that small pipe and the engine rumbled a bit and sounded like it was going to start i then put the tank back on but no still wont start.

Checked to see if fuel is infact coming out of the fuel tap and sure enough its coming out no problem.

This bike has sat for over a year and has not been started just to point out.

[stumblebum]

Have you had the carbs off and given them a good cleaning? The jets may be blocked with old fuel that's gummed up, get some carb cleaner and set too on them buggers!

[eastanglianbiker]

if its been sat that long then chances are carbs need taking off and cleaning spray a bit of carb cleaner or wd40 into air box and see it if starts then only a tiny amount tho

[berry1]

The airbox is in a VERY awkward place damn why did they have to put it there? lol looks a right pain in the arse to get to think i got to remove the carbs to actually get to the airbox this could be a job thats above my current experience to complete or maby not just looks like i got to remove the carbs completely as they are directly infront of the airbox and above the airbox is the frame of the bike so cant access from the upper level of the airbox.

Appreciate the advice though thanks

[berry1]

See what i mean? the carbs look equally hard to remove because of the frame being directly above them.

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0926_zps8198a979.jpg

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0925_zpse7fa73e6.jpg

[eastanglianbiker]

it IS a pig of a job but can be done just spray the wd40 or carb cleaner into the air intake on the airbox you dont need to open it up to do that,it might get the bike to run for a few seconds but you will still need to spend a few hours removing cleaning and replacing the carbs

[stumblebum]

Time to invest in one of these: http://www.ebay.co.uk/itm/Haynes-Kawasa ... 2ec310738e

Take your time and things will run smoothly, there's no better way to learn than to just jump straight on in there!

[berry1]

Im all for jumping straight in and going for it just worried about putting all the pipes and things back in the exact right order because theres a fair bit running into the carbs. But will give it a try

Im not 100% on where the air intake is would it work if i sprayed directly into the carbs? you know removing one of the 4 lids above the carbs and spraying directly into it?

Thanks guys

[eastanglianbiker]

no removing one of the 4 lids wont work look at the top rear of the airbox and see if you can see a long slot in casing that will be the intake or failing that if i remember corectly the filter is fitted from the side in them so open the filter bit and spray it in there

[stumblebum]

Are you using fresh fuel in the tank?

[berry1]

So i sprayed starting fluid directly into the airbox and the engine started for about 5 seconds yes STARTED! so i connected the fuel tank in a last try kind of thing just hoping that it would work but no wouldn't start. So i figured ok got to just get on with it and try and remove these carbs.

I know you can remove the carbs on a kawasaki ninja by removing some of the back end of the bike and sliding them back then out the side. So thought this might work with the gpx 600 so removed most of the back of the bike and the bolts holding the plastic in place plus a few other things but there is no chance that air box thing is going to slide back and out the side of the bike as its just to damn large to fit past the frame to slide back.

http://i1090.photobucket.com/albums/i376/monsterberry1/IMG_0926_zps8198a979.jpg

Dont see how the carbs are going to come out as the air box thing cant move back as its to large to pass the frame of the bike but it got to go back i think or the airbox tubes wont come off the tubes on the carb.

Will try and unscrew the airbox thing connected to the carbs but man the space is tiny need to try and find a screwdriver that will fit in and can still get some leverage on it still not sure if there will be enough space to get it out but will try.

stumblebum

Yeah mate i filled it with a fresh tank of nitro petrol the only petrol that was in the tank was a strange colour wasn't clear was cloudy but removed atleast 95% of it before filling with the fresh fuel i did not drain the carbs though.

Does it matter that i haven't connected the T pipe or the small output on the back of the fuel tank?

This output fitting

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0919_zps3585f923.jpg

And this T piece C

http://i1090.photobucket.com/albums/i376/monsterberry1/th_IMG_0918_zpsddcc0c4c.jpg

Once again thanks guys you been a really big help.

[eastanglianbiker]

that looks like it only the drain /air vent for the tank shouldnt need to be conected

[stumblebum]

Trace both a and b back and see where they lead, if one just comes out at the bottom of the bike it attaches to what looks like the vent ©. The air box and the carbs will come out in a certain order you just need the manual to show you the best way.