Intermittent Carb Issues
I've had my 2004 Ninja about a year now and have recently been fighting with the carbs. I went ahead and did a full rebuild as I though that would clear up most of the issues I was having:
1. One of the cylinders was running very rich to the point where I was getting white smoke out of the exhaust. During the rebuild I noticed that one of the mixture screws (the ones with the covers you have to drill out) was turned all the way in while the other side was out the 2.5 turns. I adjusted both such that they are all the way in, then 2.5 turns out.
2. During some rides after the bike seemed warm it feels like it would be running very rich and bog down, slow to react to throttle input until I got to about 5000 rpm. I assume this is when the main jets take over indicating there was a problem with the idle. When replacing the idle jets, one was very stripped out which I can only assume was affecting the fuel flow.
Both of those issues seem to have been solved after the rebuild and immediately after putting the carbs back together, and re-syncing them, the bike ran the best it ever has in the time I've owned it. However a new issues has developed that I can't for the life of me figure out. After about 5 min on a ride yesterday the bike began to bog down significantly to the point where I was having to keep it alive by revving it at stops just to get home. After stopping and attempting to diagnose the problem and restarting the bike, fuel began to pour out of the overflow line and flooded the carbs. I replaced both pilot valves and inspected the seats when rebuilding the carbs and saw no abnormalities. I'm really unsure about what could be causing that issue. It seems to be very sporadic, over the last couple days I have ridden the bike anywhere from 5 minutes to 30 minutes before the problem developed. My inclination is that it is something small because of how well it runs when it is running but I am at a loss at this point. I plan to take apart the carbs again in the next couple days and am just trying to see if anyone here has an idea of what to look for
I'd really appreciate any feedback, Thanks!