Intermittent Carb Issues - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 8 (permalink) Old 4-16-2019, 9:27 PM Thread Starter
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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!
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post #2 of 8 (permalink) Old 4-17-2019, 9:29 PM
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After setting the float heights to 17mm starting position ....you then wet tested to confirm and/or reset the actual working fuel levels?

This is the kind of information that needs to be offered voluntarily, right up front to expect pertinent, accurate answers. So anyways.....?

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Last edited by ducatiman; 4-17-2019 at 9:38 PM.
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post #3 of 8 (permalink) Old 4-17-2019, 11:41 PM
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Amen that. ^^^^

Besides that, do you have any type of fuel filter online?

I suspect that some trash from the gas tank jammed and left the float pins open.

Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -Albert Einstein.
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post #4 of 8 (permalink) Old 4-18-2019, 2:45 PM Thread Starter
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I did check the levels using the tilt test and a wet test. Both of the levels seemed to be consistent with what I've read on here (17mm on the floats and the fuel level even with the bowl joint). I do have an inline fuel filter and there doesn't appear to be any large particulates that I can see.

Thanks
post #5 of 8 (permalink) Old 4-18-2019, 2:53 PM
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The use of inline fuel filters have been historically notorious on this forum for creating weird starvation issues, usually due to extended fuel line routeing issues.

I'd suggest a test....get rid of the filter and return to stock length (I think 8 3/4") , factory routed fuel line. See if your problem disappears....

The Kawasaki rail filter https://www.ex-500.com/50-carburetor...ative-yes.html is all that is needed, unless you are expecting birds, stones or other large debris through the fuel system.

Is the tank fully clear of debris and rust?

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post #6 of 8 (permalink) Old 4-18-2019, 11:47 PM Thread Starter
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I'll look into that this weekend. Would the inline fuel filter issues cause the carbs to flood though? I ran it again today and was running super rich and dumping gas out of the overflow untill it finally died out. I could see a raw fuel spray out of the exhaust that was running rich. However the other side looked good enough to me. No white smoke or fuel in the exhaust. The tank looked clean, no rust that I could see. I had the carbs apart yesterday and gave them a good clean while checking the float levels so it seems unlikely to me that there is some particulate messing with the floats. It ran fine right after assembly, idled for about 10 min while I adjusted the idle screw, upon starting it up today it was rich and flooding again.

Thanks
post #7 of 8 (permalink) Old 4-18-2019, 11:55 PM
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Bogging and flooding may or may not be related. There may be 2 separate issues going on. You've got to use process of elimination....get rid of the filter first . If both bogging and fuel backup continues, you've got a float system issue. That would become your next repair path. If corrected, install the rail filter (no known problems over many years, many users)

Keyboard diagnosis...best I can offer...eliminate possibilities till the problem is gone.

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post #8 of 8 (permalink) Old 4-19-2019, 1:21 AM
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gas overflowing.

One suggestion that i would make is to check your fuel lines as well while it is running. I had a leak that i couldn't find and it ended up being a lose connector on my inline fuel filter which i got rid of and replaced the line with a solid line to eliminate any problems in the future since i cleaned the tank out completely and added a rail filter to the carbs.

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