1986 zl600 leaking gas

Rhamah

Active Member
Joined
Jun 26, 2012
Messages
59
Reaction score
0
Location
Louisville, KY
Took the '600 out for a ride on and noticed the throttle was a little sluggish. No biggy I thought, just some crud to blow out of the carb. Then I slow down to park it and smell gas... As I look down I see something dripping from the middle two of the 4 intake pods (bike was "jetted" before I got it). I swipe my finger through it and confirm my fears that it was indeed, gas. I turn the valve from primary to off and the leaking slows then stops. I try and figure out what's going on and my gf's dad comes out and mentions he had a problem similar to that on one of his work trucks (float valve) and he had to rebuild the carburetor. So does anyone have any good news for me? That it's and easy fix maybe? I'll take bad news only as a last resort. Sorry if I don't reply promptly, I'm in a rural area right now.
 
The PRI position is for priming the carbs if the bike has been sitting for a while, do not ride the bike in this position.

The other 2 positions are ON and REServe. These are vacuum operated, and stop flow of fuel when the bike is not running - if the petcock is operating properly.

It does sound like you need new float valves.
 
Couple of things, was the fuel petcock set to "Pri", "On" or "Res"? There is no Off. Should be set to "On" [lever down IIRC, I'm running a Pingle]. this will allow the vacuum diaphragm in the petcock to shut off the gas supply when the engine stops. "Pri" is for "Prime", if the bike has been sitting a long time and the fuel has evaporated from the carb bowls, then "Prime" bypasses the vacuum control and pours gas into the bowls [no vacuum from engine needed]. Should only use this to get bike started, then switch to "On". "Res" is "Reserve", when running in the "On" position and the gas gets too low, the bike will start to stutter like its out of gas [which it effectively is at that point. "Reserve" lets you tap into the last gallon in the tank so you can get to a gas station.

All that being said, if you were running in prime, it would be fairly easy to blow past the float needle valves. Theoretically they should be able to handle the pressure, but as they get older they don't seat as well. Couple of suggestions:
1) DON'T TRY TO START THE BIKE!! Okay, that's a little stronger than a suggestion. What can happen in your situation is that liquid fuel will build up in the #1 cylinder [it's the lowest when the bike is on the stand] and when you try to start the bike the liquid won't compress, leading to a bent rod. Many examples of that on the site, search the threads.
2) Make sure gas isn't continuing to flow, and then pull the plugs and crank the bike over to expel any liquid gas that's in the cylinders. Make sure you unhook the plugs from the wires and keep the wires as far back on the bike and away from metal, you don't want a spark to ignite any gas coming out of the cylinders.
3) After your sure the cylinders are clear, change the oil. If your petcock is working correctly, you should be able to set it to the "On" position and ride the bike. If gas continues to drip or accumulate in the airbox, you'll probably need to rebuild the petcock and/or carbs. Luckily for you, there are members on the site that do both; contact Markus56 about rebuilding the petcock, and WickedZL900 about rebuilding the carbs. Both do excellent work.
 
I DID ride it in in the prime position (straight up and down). I thought I had turned it off while I was working on it because... I thought I HAD an off. I realized my mistake approx 10mi down the road. And that's right before all this started. Great. Thanks for the info, I've got it at a mechanic friends house now so hopefully I haven't damaged it too much with my ignorance. Previous owner said he rebuilt the petcock a coupla hundred miles ago so hopefully it held up. Prices for a rebuilt carb/petcock? Nothing too specific, just looking for a ballpark.
 
Sorry, can't edit my previous post from my phone. Looks like I've BEEN riding it in the prime position. I assumed pri stood for priMARY, and so, this headache ensued. I'd say I've put ~100mi on it like this.


... Let this be a lesson to you kids.
 
Have you had a chance to go through the owner's manual? Covers some other things [like shock and fork air pressure] that are good to know about.
 
Back
Top