'86 Zl600 gas problems

Rhamah

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Jun 26, 2012
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Location
Louisville, KY
The problem:
I took it out for a ride with my girlfriend, and it performed stellar for 30 miles or so. I drop her off and am on my way home when I realize I've been riding on about a quarter of a tank. So I stop off at the nearest gas station and put about $10 in premium on a whim. This almost fills her up so I start to ride home. About a 5miles down the road I start to notice a loss in power. Being only a mile or so from home I gun it and coast in. As I pull in I notice a hose hanging off the side and gas leaking out. I quickly reattach it and park. (it was the hose from the tank to the plastic T connector.) So I figure hey, problem solved. Later that night, I hop on to head to my buddies in town and about 1/2 mile away, I slow down at a stop sign. It loses power again until it dies. ****. Gas is leaking out of the intake pods (aftermarket cones instead of the box) and my pants smell. So I leave it for the night and go out. I go back in the morning and see if it starts. It does. So I take off, get 1/4mile down the road, and it stalls out. Outta gas. I fill up a Jerry can, put about 1/2 gal in it and try and start it. It takes the choke AND the throttle on max to get it to catch. Then I high tail it home (6miles away) park it, and let it sit until I pull the petcock later.

Things to know:
1. Being a newbie I rode the first 100 miles or so in the "prime" position.
2. It's done the "gas coming out of the intake" before. A coupla times.
3. I found a coupla bits of flimsy plastic in the gas tank when I drained it. I assume from the guy I bought it from's rebuilding of the petcock.
4. It has bigger jets installed, and so the need for the aftermarket cones. Also from the previous owner.

Theories:
1. Blew the float valve, needs a rebuild.
2. Petcock is busted. Hopefully I'll know this week.
3. That plastic piece I pulled out was blocking the gas flow or vacuum and now I've fixed it.
4. The hoses suck and need replacing.

I pulled the petcock and will hopefully get it checked soon, but the bike is 250 miles away while I'm at college and can't test anything else.
 
My first guess, the petcock. It is vacuum operated so if you have a bad diaphragm, it flowing when it shouldn't or its sucking fuel thru the vac like. Second issue, the float needles are not shutting off the flow when the bowls are full or the floats are set too high. I like to check easy things first but you dont want to be riding with fuel coming out the filters. If you get too much fuel in the oil, very bad things can happen.
 
+1, check all the simple stuff first, pull the petcock and make sure it is still in one piece. If so, then check to see if it is working properly, I would run a hose from it to a can and make sure it flows on prime and doesn't flow on "on" or "res". If that all checks out, you might have junk in the carb bowls keeping the float needles from seating, best solution is to pull the carbs off, take the bowls off the bottom of the carbs and inspect and clean.
 
Don't run it again until you change the oil!! Good probability that some of that gas got down in the oil, bad thing.
 
Don't run it again until you change the oil!!

Will do. Without the petcock it can't go anywhere ;). It really sucks being so far away from it until the weekend. I was going to ride it up and park it here from now on, but then this happened. I brought the petcock with me because markus56 and I happen to live in the same town and I was hoping he could take a look at it for me. Next step would be to remove the carb and change the oil (weeks from now). Thanks for the help guys.
 
+2 on the carbs. I had a FJ1200 with just a few tiny bits of muck that keep the floats from sealing correctly....same thing gas spilled out till the float bowls were low enough.It doesn't take much to upset float bowl levels. I installed an in-line fuel filter so I didn't have to rely on the cheesy screen filter of the petcock. Bacchus has top 'o' the line Pingle filters....but if money is tight....a Napa or (if you have to)fram inline filter will work. BUT DON"T use Fram oil filters....
 
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