Fuel !

[Cheekyfork]

Hi, newbie to the group, long time sufferer...lol...

 

I have a ZZR600 1995 (e), was a great bike for the year I rode it, but after getting some rubbish from the tank into the carbs I decided to strip and clean carbs.

 

They have been stripped and rebuilt 3 times. Twice I was subjected to flooding...

Floats now set with a float tool and yesterday it ran well, started 1st time and idled (with revving) for over 10 mins after finally stalling..

I've found fuel in my oil, which I will drop tomorrow...

 

What the heck is going on, why can't I sort this...

 

Below is a list of parts I've changed :

 

float bowl seals (two brand new sets)

float needles

o-rings in seats and air/fuel

Fuel line o-rings

fuel filter

float seats, replacement ones didn't seem to seal or sit right, and I got flooding, so I cleaned up the old ones and reinserted.

 

 

 

 

 

 

 

 

 

 

[Copycat73]

did you turn the fuel off before you locked it up ?

[Cheekyfork]

Not sure tbh......?

[husoi]

You don't mention cleaning the tank.

Try some seafoam with the petrol to clean it up.

Fuel in the oil could just mean excess petrol into the engine.

If you have to rev it to keep the idle then your mix is too lean. have you changed the setting on the pilot jets?

Is the air filter new or dirty old?

Have you cleaned the spark plugs?

10min running would assume choke off.

Do you use choke to start it? If not then the pilot jets need closed as the mix will be too rich

[Cheekyfork]

Appreciate your help

 

A) no I've not cleaned tank

b)didn't need to rev it to keep it going, it was idling nicely, I just revved it to check responsiveness

c)I out the pilot jets back in as found

d)air filter is fine

e)plugs are only 500 miles old and clean

f)10 min idling was choke off

e)the choke was used momentarily

 

 

 

 

[husoi]

I find it strange that with a new filter dirt would get into the carbs. However, as you say it happened before.

 

I know it is a stupid question...

Have you by accident press the kill switch? 

[Cheekyfork]

No....lol...it wouldn't have run for 10 mins and then stalled.....??

 

And there's fuel in the oil

[Stu]

Was the fuel in the oil from before? 

 

If you had a leaking float then it can fill the sump 

[Cheekyfork]

I have to be honest, I never noticed the increased oil level until yesterday after it ran and died.

 

Previously other attempts have failed due to clear flooding from the carbs, so it could have been there...

 

Still don't understand how it can run so well and stop after 10 mins ?

[onesea]

6 hours ago, Cheekyfork said:

 

Still don't understand how it can run so well and stop after 10 mins ?

Could it be electrical, plenty of electronics loose efficiency with heat.

Did it cut out Sharp or misfire?

Did it start again after?

[TimR]

How did you find Fuel in your oil ? 

 

 

Check the fuel pump power as these are common to having issues with wiring connections overheating and giving intermittent power .

 

It can range from the ignition switch back to the relay ...

 

Try appling a direct 12v feed to pump as a test 

 

Check you have not kinked a hose under the tank  , again quite a common occurrence 

 

 

[TimR]

And are you following the manual for float setting or just using this ' tool ' ? 

[Cheekyfork]

27 minutes ago, TimR said:

And are you following the manual for float setting or just using this ' tool ' ? 

Both.....

[Cheekyfork]

3 hours ago, TimR said:

How did you find Fuel in your oil ? 

 

 

Check the fuel pump power as these are common to having issues with wiring connections overheating and giving intermittent power .

 

It can range from the ignition switch back to the relay ...

 

Try appling a direct 12v feed to pump as a test 

 

Check you have not kinked a hose under the tank  , again quite a common occurrence 

 

 

I noticed my oil level had gone up and it's not water..

 

I don't think the pump isn't working, I do t think it's fuel starvation, more over fuelling?

[TimR]

1 hour ago, Cheekyfork said:

I noticed my oil level had gone up and it's not water..

 

I don't think the pump isn't working, I do t think it's fuel starvation, more over fuelling?

Am.on about the running for 10mins than the fuel in oil. The pump will prime on start up filling the system but will not activate afterwards so only allowing the pipework of fuel to run through the carbs ... Which can result in more sediment and crub being dragged through ...

 

 

 

[Grommet]

Check if the floats seal if rubber tipped and brass, polish brass and replace float valves and check float height.