Possible carb issue - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 9 (permalink) Old 7-26-2019, 2:04 PM Thread Starter
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Possible carb issue

I believe I have a carb issue causing bike not to get gas to 1 cylinder. Bike was running great, I had adjusted valves, cleaned carbs, new plugs and plug boots and trimmed spark plug wires, had removed the CA emissions stuff and done the pair removal several weeks earlier and bike ran great for the several weeks after that. Also did fog mod about 2 weeks ago without any issues in the 2 weeks since. A couple days ago I rode home from work, bike was running fine with full power, but then upon stopping at my garage to park, the bike was only idling on 1 cylinder. I have verified spark is good on both sides and plugs are good. If I give it choke the other cylinder starts running. I took the carbs off, ran some guitar string through the pilots and blew some compressed air throught them and air came out the other side of the circuit. I also did the clear tube test to check fuel level in the float bowls and both sides looked great. I also threw new o rings on the fuel rail while carbs we're apart as I had noticed they were leaking previously. I put the carbs back on and started bike, still runing on 1 cylinder and now it seems to not matter if choke on or off. Took carbs back off, When taking the carbs off, I noticed that the running side has some fuel on the inside of the boot going into the engine, the non running side is completely dry. I also noticed when draining the float bowls this time, the running side was holding a lot more gas than the non running side. This is interesting as the clear tube test before showed good float levels. Any suggestions on where to start? Do I need to possibly clean or replace the float valves? When I put the carbs back on I could hear the float valves clicking open and closed when I tilted the carbs.
Thanks, Zach
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post #2 of 9 (permalink) Old 7-26-2019, 2:31 PM
fog
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Didn't see where you synced the carbs.'Maybe the dry side throttle is closed

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post #3 of 9 (permalink) Old 7-26-2019, 2:53 PM Thread Starter
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I made one of those manometers with the two glass bottles connected with clear tubing to sync and synced the carbs after adjusting the valves and resetting the pilot screws. And when I had the carbs off I verified the throttle plates are even and both open when the throttle cable is pulled. Is there something else I should be looking for to check that the one is not closed? Maybe a dumb question, but they should both be closed or almost closed at idle, right?
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post #4 of 9 (permalink) Old 7-26-2019, 4:00 PM
fog
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They should be open a crack. your trouble might still be ignition. verify your wire connections are ingot order.
Often a plug that fires in free air will short under compression

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post #5 of 9 (permalink) Old 7-26-2019, 4:36 PM
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Quote:
Originally Posted by Zmills View Post
.... I also noticed when draining the float bowls this time, the running side was holding a lot more gas than the non running side. This is interesting as the clear tube test before showed good float levels....
Repeat the test. What do the tubes look like now that you are experiencing issues. If one float bowl has less gas than the other, then you have fuel issues. I would inspect and clean the float valve assembly as a minimum.

If fuel is OK then FOG is onto something about a lack of spark.

2007 Kawasaki EX-500 Ninja
2003 Honda Goldwing
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
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post #6 of 9 (permalink) Old 7-26-2019, 5:42 PM Thread Starter
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Ok great, they are both open a crack, I will check those connections this afternoon when I get home. I'm assuming it's still abnormal and unrelated that one side appears to have fuel going to the engine and the other doesn't?
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post #7 of 9 (permalink) Old 7-26-2019, 5:44 PM Thread Starter
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I will clean the float valves and recheck fuel levels as well
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post #8 of 9 (permalink) Old 7-27-2019, 11:03 AM Thread Starter
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Last night I pulled the carbs apart, let the Jets and pilot needle sit in carb cleaner overnight. This morning got up at 4am and cleaned out the carbs very thoroughly with the spray cleaner and guitar string with special attention to the pilot circuit. Cleaned both float valves and made sure they were both opening and closing and then reassembled. Tested the gas level in both bowls and they were perfect. Stuck the bike back together and fired her up and BOOM, running like a champ on both cylinders 😀. Thanks for the ideas guys. Can't wait to get out and ride this weekend!!!
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post #9 of 9 (permalink) Old 7-27-2019, 12:25 PM
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Every time I hear(read) the words, "I cleaned the cabs, but...?" I cringe and wait to offer any other remedy. so often the thoroughness required escapes a first timer until the third or forth time around.
I congratulate you on getting it done properly after only 2 tries

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