Gas coming out of exhaust manifold - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 27 (permalink) Old 12-14-2010, 1:59 PM Thread Starter
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Gas coming out of exhaust manifold

I tried to start my 92 500 ex on a cold morning and gas was coming out the front exhaust manifold and I let it sit.I caught the bike on a good day and rode it about 40 Min's it rode OK until it started to get sluggish and idle was low so I went home.when I tried to start it again there it was gas coming out manifold. i corrected the throttle and stop cables which were bad off but of course still floods out.From reading a little bit hear i see I need to check fuel level in floats and probably check or replace float.Can I clean that float bole without new parts or a partial dissemble and clean.where should I start.I only had this bike for a few Weeks its all I got.
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post #2 of 27 (permalink) Old 12-14-2010, 2:11 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
I tried to start my 92 500 ex on a cold morning and gas was coming out the front exhaust manifold and I let it sit.I caught the bike on a good day and rode it about 40 Min's it rode OK until it started to get sluggish and idle was low so I went home.when I tried to start it again there it was gas coming out manifold. i corrected the throttle and stop cables which were bad off but of course still floods out.From reading a little bit hear i see I need to check fuel level in floats and probably check or replace float.Can I clean that float bole without new parts or a partial dissemble and clean.where should I start.I only had this bike for a few Weeks its all I got.
A munged-up float usually causes fuel to come out of the overflow hose. Do you have gas dripping on the grounds below your carbs?
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post #3 of 27 (permalink) Old 12-14-2010, 2:21 PM Thread Starter
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Re: Gas coming out of exhaust manifold

Yes just little drips. The most is coming out the hole in the left side between cooling fins and manifold.
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post #4 of 27 (permalink) Old 12-14-2010, 2:31 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
Yes just little drips. The most is coming out the hole in the left side of the head under the spark plug and manifold.
The small round hole between the cooling fins on the left side of the engine block?
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post #5 of 27 (permalink) Old 12-14-2010, 2:55 PM Thread Starter
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Re: Gas coming out of exhaust manifold

Yes
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post #6 of 27 (permalink) Old 12-14-2010, 3:17 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
Yes
Are you sure it's gas? That hole is a drain for the spark plug well, so that any water that gets in there can drain out. If there is a persistent leak the usual cause is a leaking o-ring on one of the coolant tubes that go into the head. If so, that's a pretty easy fix.
post #7 of 27 (permalink) Old 12-14-2010, 3:25 PM Thread Starter
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Re: Gas coming out of exhaust manifold

Yes it is absolutely gas. If my gas tank was on it would drain empty,when I try to start it comes out manifold. do you think i should take carb off. O my gas tank has lots of rust in it.
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post #8 of 27 (permalink) Old 12-14-2010, 3:45 PM
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Re: Gas coming out of exhaust manifold

First of all pull the freaking tank and inspect the fuel lines and the bottom of tank
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post #9 of 27 (permalink) Old 12-14-2010, 4:34 PM
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Re: Gas coming out of exhaust manifold

Your tank is leaking and your about to blow up, I'm supprised you haven't already.

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post #10 of 27 (permalink) Old 12-14-2010, 5:04 PM
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Re: Gas coming out of exhaust manifold

Those petcocks will leak like a sonuva bitch.
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post #11 of 27 (permalink) Old 12-14-2010, 5:15 PM
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Re: Gas coming out of exhaust manifold

On a 92 it's very likely that a seam rotted out I have seen many such tanks due to water in the gas. The way the tank is made make a very narrow point all around the outer edge where it two pieces are welded together.

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post #12 of 27 (permalink) Old 12-14-2010, 6:28 PM
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Re: Gas coming out of exhaust manifold

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Your tank is leaking and your about to blow up, I'm supprised you haven't already.

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Thats exactly what I was thinking.

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post #13 of 27 (permalink) Old 12-15-2010, 7:18 AM
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Re: Gas coming out of exhaust manifold

He says it only leaks when the engine is running or when he is trying to start it. Wouldn't that translate into a petcock or fuel line leak? If his tank was leaking wouldn't the petrol come out ALL the time?

You got to look at ALL the clues!

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post #14 of 27 (permalink) Old 12-15-2010, 7:54 AM
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Re: Gas coming out of exhaust manifold

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Originally Posted by FloridaEX500
He says it only leaks when the engine is running. Wouldn't that translate into a petcock or fuel line leak? If his tank was leaking wouldn't the petrol come out ALL the time?
Yeah, he said this...
Quote:
Originally Posted by neo666
If my gas tank was on it would drain empty
... which would imply that it doesn't leak if the petcock is off. It sounds like the vacuum mechanism isn't working, and I'm guessing bits of the gas tank rust he mentioned are keeping the float needle from closing, and enough gas is getting in the cylinder that it gets pumped out when he tries to start it. But what's confusing is his description of where it's leaking. First off, it can't leak out the exhaust manifold because the engine doesn't have one. It shouldn't leak at the top of the header pipe unless there's a major exhaust leak there. And it shouldn't leak out the spark plug well drain hole unless there's a loose spark plug.
OP, Remove the gas tank, check the underside for leaks, check for loose spark plug, check to see if fuel runs out the petcock when you turn it on. It shouldn't unless vacuum is applied to the small hose. If it does, you should rebuild the petcock. And, you should remove the float bowls and check for junk in there, remove the floats and needles, check the seating surface of the needles for damage. You can do this with the carbs on the engine. Better yet, remove them and do a complete carb cleaning. No need to buy any gaskets. Also, get that rust out of the tank. I think if you research the wiki you will find instructions on how to do all these things. Let us know what you find.
post #15 of 27 (permalink) Old 12-15-2010, 12:58 PM Thread Starter
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Re: Gas coming out of exhaust manifold

the gas tank is not on the bike .i use a container with an open end,but when i close that end the gas didn't leak .does the gas container have to be in a vacuum,it does not leak when bike is running but idle is low and it kills when i give a little gas. OK I'm going to take the carb out and set the pilets to 2 1\4 turns per carb and synk ,first im going to put tank back on an turn it on and see if it drains sitting and while I start . PS im tryn fellas
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post #16 of 27 (permalink) Old 12-15-2010, 1:42 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
the gas tank is not on the bike .i use a container with an open end,but when i close that end the gas didn't leak .does the gas container have to be in a vacuum,it does not leak when bike is running but idle is low and it kills when i give a little gas. OK I'm going to take the carb out and set the pilets to 2 1\4 turns per carb and synk ,first im going to put tank back on an turn it on and see if it drains sitting and while I start . PS im tryn fellas
In my opinion you are going about this completely wrong. If gasoline is pouring out of your bike I think it's pretty obvious, at least to most, that THAT is the place to start; not syncing the carbs.

First determine if it an external leak (e.g. damaged fuel tank, leaking petcock, etc). If not than it's the carb. You need to remove the carbs and rebuild them.
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post #17 of 27 (permalink) Old 12-15-2010, 2:14 PM
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Re: Gas coming out of exhaust manifold

Quote:
Originally Posted by neo666
the gas tank is not on the bike .i use a container with an open end,but when i close that end the gas didn't leak .does the gas container have to be in a vacuum,it does not leak when bike is running but idle is low and it kills when i give a little gas. OK I'm going to take the carb out and set the pilets to 2 1\4 turns per carb and synk ,first im going to put tank back on an turn it on and see if it drains sitting and while I start . PS im tryn fellas
Vaccuum leak because your tank isnt on and you didnt plug the port on the carbs. This is a simple petcock/ float failure.

Put the tank back on, renew replace fuel lines. If its still leaking inspect the petcock and find the leak. Dont touch your carbs yet. Find and fix the gas leak and then assess running.
post #18 of 27 (permalink) Old 12-16-2010, 12:54 PM Thread Starter
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Re: Gas coming out of exhaust manifold

I was checking the left spark plug to see the spark and gas glopped out of the spark plug hole into my mouth and face;i got lucky again.
I went straight to taking carb out, there was no left pilot screw,spring or washer.There was a little bit off fine rust build up in the corners of float bowl and near drain hole but float look like it sat well on an angle. I didn't mess with diaphragm yet because one screw was rung out at the top.
I don't know if a missing pilot on the right side would make the fuel leak from the left side or if the gas is supposed to glop like that it didn't before but that may be the rust doing that to the jets. P.s I'm thinking I was mistaking about the gas coming out the manefold it must have trailed from somewhere else but it did come from hole by fin fan.
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post #19 of 27 (permalink) Old 12-16-2010, 2:27 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
I was checking the left spark plug to see the spark and gas glopped out of the spark plug hole into my mouth and face;i got lucky again.
I went straight to taking carb out, there was no left pilot screw,spring or washer.There was a little bit off fine rust build up in the corners of float bowl and near drain hole but float look like it sat well on an angle. I didn't mess with diaphragm yet because one screw was rung out at the top.
I don't know if a missing pilot on the right side would make the fuel leak from the left side or if the gas is supposed to glop like that it didn't before but that may be the rust doing that to the jets. P.s I'm thinking I was mistaking about the gas coming out the manefold it must have trailed from somewhere else but it did come from hole by fin fan.
Gas goes:

Tank -> petcock (on/off/res + diaphragm) -> fuel line -> carb entry hole -> past float valve -> float bowl

I don't think that any pilots would cause fuel leakage since the fuel goes right into the float bowl. If the level gets too high the floats raise and the float valve SHOULD seal off the access hole.
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post #20 of 27 (permalink) Old 12-16-2010, 3:10 PM
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Re: Gas coming out of exhaust manifold

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Originally Posted by neo666
I was checking the left spark plug to see the spark and gas glopped out of the spark plug hole into my mouth and face;i got lucky again.
I went straight to taking carb out, there was no left pilot screw,spring or washer.There was a little bit off fine rust build up in the corners of float bowl and near drain hole but float look like it sat well on an angle. I didn't mess with diaphragm yet because one screw was rung out at the top.
I don't know if a missing pilot on the right side would make the fuel leak from the left side or if the gas is supposed to glop like that it didn't before but that may be the rust doing that to the jets. P.s I'm thinking I was mistaking about the gas coming out the manefold it must have trailed from somewhere else but it did come from hole by fin fan.
seriously... ur beyond help if your going to ignore what people suggest... Why post on a forum with questions if you want to just do it wrong anyways? there is gas in your spark plug hole because you hydrolocked your engine. You need to pull both plugs and hit the starter to shoot the rest of it out. Then you need to fix your petcock. Then you need to assess running. Then with a fixed petcock you can probably just run seafoam through your carbs to fix the float issue...

this is a 30 minute job... your making this rediculous.
post #21 of 27 (permalink) Old 12-16-2010, 3:31 PM
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Re: Gas coming out of exhaust manifold

OK, the thing we all want to know is; How did the gas get into the spark plug well? That's bad, and there's only three ways it could get there. 1) It dripped down from the fuel tank above 2) It got pushed out of a badly flooded cylinder past a loose spark plug. 3) An enemy or a gremlin is pouring it in there in an attempt to destroy you. You still haven't told us which.
post #22 of 27 (permalink) Old 12-16-2010, 5:06 PM
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Re: Gas coming out of exhaust manifold

It's most likely the petcock letting gas past and a bad float. Idk if you turn off the petcock does it eliminate it? If you had a ducati it would be 5 times as expensive and you'd be a pro mechanic by now.

Stop crying and Ride!
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post #23 of 27 (permalink) Old 12-16-2010, 6:08 PM
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Re: Gas coming out of exhaust manifold

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Take carb apart clean best I can with WD40 and put back .
why would you use wd40? its not for cleaning.

just go to autozone or napa and buy a big can of carb cleaner.
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post #24 of 27 (permalink) Old 12-16-2010, 9:08 PM
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Re: Gas coming out of exhaust manifold

This thread is starting to hurt my head. The level of ridiculousness is excessive.
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post #25 of 27 (permalink) Old 12-17-2010, 11:42 AM
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Re: Gas coming out of exhaust manifold

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Originally Posted by desertrat748
It's most likely the petcock letting gas past and a bad float. Idk if you turn off the petcock does it eliminate it? If you had a ducati it would be 5 times as expensive and you'd be a pro mechanic by now.
1) If it is a carb float issue this will push gas into the cylinder. So no this is not the issue. Also if the float fails the petcock valve will still prevent fuel flow if it is working properly.

2) As the OP questioned about gas getting into the manifold... the 500 does not have a manifold - the exhaust exits the engine via header pipes.

3) as other posters haves stated - it is a GAS LEAK THAT IS DRIPPING GAS ON TOP OF THE ENGINE if it is coming out of the drain holes on the side of the engine

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