I have got to be doing something wrong - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 17 (permalink) Old 6-14-2015, 8:07 PM Thread Starter
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I have got to be doing something wrong

So I've rebuilt my carbs, I set my float height to 17mm and the carbs were still leaking into the crankcase. I pulled the carbs again and to check the float needles I took the bowls off and held the carb sideways and filled the vent tube. Gas stayed in the vent tube line and didn't leak any until I turned the carb and opened the needles. GREAT! So I thought that narrowed it down to float height. I've adjusted the heights all the way down to 20mm from the lip of the float body and soul hen I pour in gas thru the gas lines it pours out of the main jet circuit (carb off bike) and the pilot hole (inside the carb not outside) . Shouldn't gas stay in the fuel line and the float needles keep this from happening? I've taken off my float and submerged them in water to make sure there were no leaks. I've tapped the carb to make sure the needles were seating. And there is absolutely no trash in the carbs. The vacuum nipple is open when I'm pouring in the gas. What am I missing?
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post #2 of 17 (permalink) Old 6-14-2015, 9:53 PM
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Re: I have got to be doing something wrong

You haven't done it correctly.
That's what you're missing.
There's a few of us that can set up the carbs. We can only explain it so much.
When it comes to the failure of reading it's time to send them to us that can fix them.

It's a simple PM.

O_E_M
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post #3 of 17 (permalink) Old 6-14-2015, 10:07 PM Thread Starter
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Re: I have got to be doing something wrong

If I can't fix it, I will be shipping it out to someone. But my question is, what would still cause this problem? Does the vacuum open when I'm bench testing matter? Aside from that, I know it's assembled correctly, the floats are set to spec, the floats aren't broken, the float needles are new, all the gaskets and o-rings are new, it's clean, has and has a fuel filter.
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post #4 of 17 (permalink) Old 6-15-2015, 10:33 AM
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Re: I have got to be doing something wrong

The fuel "IN" circuit is completely independent. it is simply the float valve blocking the fuel. operated by the float. Your leaks are cause by the needles not making a seal at the valve body. .
no other component of the carbs is involved.

FOG


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post #5 of 17 (permalink) Old 6-15-2015, 10:47 AM
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Re: I have got to be doing something wrong

One thing I always do is to polish the valve seat. I take a Q-tip in a drill with a little polishing compound on the end and clean up the seat.

Psychedelic Relic, I should have taken the blue pill......<br />1992 EX500A6 AKA Pinkie (SOLD)<br />1987 ZX750F1 AKA Vader<br />1991 Zephyr 550<br />2001 500R trackday Weapon
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post #6 of 17 (permalink) Old 6-15-2015, 10:54 AM
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Re: I have got to be doing something wrong

Being assembled correctly and the being rebuilt correctly are two different things.

You can put it together all day long but if you didn't do it correctly then you're pissing in the wind.

O_E_M
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post #7 of 17 (permalink) Old 6-24-2015, 6:28 PM
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Re: I have got to be doing something wrong

Maybe between 10-20% of the time after a carburetor rebuild, this will happen as a float valve gets jammed when the carburetor is refilling. I just drain the gas from the bottom and re-float it. So far it never seems to happen the second time
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post #8 of 17 (permalink) Old 6-24-2015, 10:29 PM
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Re: I have got to be doing something wrong

OP: The 17mm spec isn't the end-all-be-all of float height adjustment. Try the tube method, discussed here.

Also, if you're doing it wrong, I'd strongly suggest you persevere and learn how to do it right. It's nice that guys like duc and O_E_M provide their services for us on the forum, but there's nothing stopping you from learning.


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post #9 of 17 (permalink) Old 6-25-2015, 6:59 AM
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Re: I have got to be doing something wrong

The above post about the clear hose test reminded me that I bench test the carburetors that way. Just use a funnel and a rubber hose to the carburetor instead of the petcock and see what happens off the bike as you fill it. It is a lot more convenient than installing and uninstalling the carburetor.
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post #10 of 17 (permalink) Old 6-25-2015, 7:53 AM
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Re: I have got to be doing something wrong

Quote:
Originally Posted by solidxsnake
OP: The 17mm spec isn't the end-all-be-all of float height adjustment. Try the tube method, discussed here.

Also, if you're doing it wrong, I'd strongly suggest you persevere and learn how to do it right. It's nice that guys like duc and O_E_M provide their services for us on the forum, but there's nothing stopping you from learning.
until half your riding season is spent endlessly farting around

buy refurbs from me and ride.....meanwhile learn on yours
or send me yours and end the torture

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #11 of 17 (permalink) Old 6-25-2015, 6:39 PM
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Re: I have got to be doing something wrong

You can get gas in the crankcase without it being the carburetor.

I worked on a bike once where the petcock had a punctured diaphragm. The engine intake vacuum was sucking fuel out of the petcock directly into the engine via the petcock vacuum line. The give away was that when I disconnected the vacuum hose, fuel dribbled out.

I just came back from another forum where the same thing happened. The guy replaced the carburetor and the problem was still there because it was the petcock.

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post #12 of 17 (permalink) Old 6-25-2015, 9:14 PM
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Re: I have got to be doing something wrong

Hey, great idea. Send me both carbs and petcock, I'll test both, service just the faulty component.

Coincidence....I just happen keep a gen-you-wine Kawasaki petcock rebuild kit in stock.

Oi, such a deal

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #13 of 17 (permalink) Old 6-25-2015, 9:17 PM
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Re: I have got to be doing something wrong

Quote:
Originally Posted by ducatiman
Hey, great idea. Send me both carbs and petcock, I'll test both, service just the faulty component.

Coincidence....I just happen keep a gen-you-wine Kawasaki petcock rebuild kit in stock.

Oi, such a deal
Not a gen-you-wine one!
Can't beat that.

O_E_M
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post #14 of 17 (permalink) Old 7-2-2015, 9:33 PM Thread Starter
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Re: I have got to be doing something wrong

Well I'm man enough to admit after about 6 attempts and gas still leaking, ducatiman, you will be receiving my carb in the mail.
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post #15 of 17 (permalink) Old 7-2-2015, 10:05 PM
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Re: I have got to be doing something wrong

at your service, adio

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #16 of 17 (permalink) Old 7-8-2015, 2:32 PM
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Re: I have got to be doing something wrong

adio all fixed up, basic spilt/service....in addition a defective float valve (from one o' my carb kits). But he had posted changing a float valve with an old one? ...regardless I replaced FOC, no questions asked.

Also a misconception re: assembly on his part which he now understands.

Carbs shipped 7/8. All should be well in adio-land.

Bolt 'em up, let em fill....hit the button...let us know, adio.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #17 of 17 (permalink) Old 7-8-2015, 11:50 PM
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Re: I have got to be doing something wrong

👍🏻

O_E_M
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