ZL400 Not running properly.

WeeJen

WeeJen

Active Member
Joined
Apr 20, 2011
Messages
29
Reaction score
0
Location
Fife, Scotland
My wee bikey's not going properly.

It revs up fine in 1st, 2nd and 3rd, but in 4th, 5th and 6th it'll only rev to about 6000rpm. It's not pulling right either when it's in the top 3 gears. It's also cutting out. Petrol tank is clean, venting and petrol's flowing properly. Electrics have been thoroughly checked. I can't think what else to try!

Any suggestions?
 
:hello:Valves may be a little on the snug side. When is the last time they were checked. How may miles are on it.
 
Thanks RJ!

No idea when they were last checked. I got the bike in 2011 when I passed my test and it's not been done since then.

Bike's done 41801Kilometers... About 26k miles. :)

What should the valve clearances be?

Thanks for your help! :D
 
WeeJen said:
Thanks RJ!

No idea when they were last checked. I got the bike in 2011 when I passed my test and it's not been done since then.

Bike's done 41801Kilometers... About 26k miles. :)

What should the valve clearances be?

Thanks for your help! :D
Click to expand...

:hello:Not sure. Here in the States for some reason KAW thought there was no reason to let us have ZL 400s. R. J.
 
:( It's a grey import into the UK too, so no info here either. I've got the downloads for the ZL400 and ZL600.

Going to have another look at it tomorrow. Going to check the vent in the cap and the flowrate thru the filters etc. May take the carbs out again for a wee spring clean. :)

Thanks! :)
 
WeeJen said:
My wee bikey's not going properly.

It revs up fine in 1st, 2nd and 3rd, but in 4th, 5th and 6th it'll only rev to about 6000rpm. It's not pulling right either when it's in the top 3 gears. It's also cutting out. Petrol tank is clean, venting and petrol's flowing properly. Electrics have been thoroughly checked. I can't think what else to try!

Any suggestions?
Click to expand...

:hello: When you take the carbs off check the rubber vacuum slid gismos under the caps for cracks. They my be dropping to soon when under hard acceleration in the higher gears. Check for that suction noise they make. R. J.
 
Found out what's wrong! :D :thumbsup:

The rubber bits going from the airbox to the carbs are not attached properly and are old and inflexible.

Went to see the nice Kawasaki mannie in the big green Kawasaki shop and they don't make 2 out of 4 of them. :(

He's saying get rid of the airbox and fit K&N filters, but that'll mean re-jetting. I don't really understand what he's on about, apart from it's going to cost me a bloody fortune! :(

Anyone got any suggestions?
 

Attachments

  • IMG-20130305-03241.jpg
    IMG-20130305-03241.jpg
    66.1 KB · Views: 16
:hello: Are they the air ducks between the motor & carbs or the ones from the carbs to the air cleaner. If the later the K & N pods will work. Most of the time you can go up one size on the main jets & one size on the pilot jets. It also depends on elevation. Also may have to raise the needles one notch. R. J.
 
Last edited:
:hello: If there are no holes in them or not cracked you can soften them up with a penetrating oil like WD 40 or a rubber enhancer like Armor All. Also I found that brake parts cleaner/carb cleaner will expand the rubber to get the boots to go back on. They shrink over time from age & heat off the motor. If they came with springs that hold the boots to the air box & you can not get new ones you can use safety wire to secure them to the air box. Also if there is enough room you can use thin/narrow hose clamps. I would order the 2 that are still available & try to find the other 2 used that are better than what you have. R. J.
 
I would think the ZL600 boots are still available and I would bet they are the same part. I know these can be ordered in the US. I got a set about a month ago. I tried to use old ones and about killed myself. The new one popped on in about 10 minutes and fit very well.
 
RJ,
That is the same ZL400 Microfiche we have in the download section. No part number in it at all....
 
Thanks guys.

I've already got the part numbers that I'm looking for as I've got the manuals from the downloads section of the forum. Nothing found in the UK and Europe and I doubt I'll find anything in USA as, from what I can tell, they weren't meant to be exported from Japan. :( Need to learn Japanese and go hunting. ;)

I'm not keen on using 2nd hand parts either, as they're going to be from 1991 at the latest.

I'm going to see how I get on with pods and re-jetting. I've got the tools, I just need the confidence! It's coming up to riding season too, so I don't want much more down time! :(

Thanks for your support, Gentlemen! :) :thumbsup:
 
Jen,
I have pods on my 600 and I love them. I have a slight popping about 7,000 rpm but it pulls like a train. It runs so good I put up with a pop or two.
 
What is the part number/s you are looking for? They may have been used on other bikes/ other years so there would be a slight chance they could be purchased new or possibly here in the states? Later.
 
Jarney said:
What is the part number/s you are looking for? They may have been used on other bikes/ other years so there would be a slight chance they could be purchased new or possibly here in the states? Later.
Click to expand...

:hello: That is a good idea if the same part #s are used in all Countries. Some parts sights have a cross reference page. So post up the part #s. We can see if we can help. R. J.
 
Part numbers are 14073A and 14073B.

One is the inner set and one is the outer. Can't remember which is which but the inner ones are no longer available to Kawasaki dealers. :(

Cheers! :)
 
:hello: Need complete part #s. They should be @ 9 #s long with a - between them. The following is from a 1987 ZL 600. 14073-1211 Carb Ducts x 4. $26.44. 14073A = 14073-1249. Duct LH. $14.55. 14073B = 14073-1250. Duct RH. $14.55. 14073C = 14073-1251. Air Intake Duct. $8.57. These parts are all available. Get back to us with the complete part #. R. J.
 
Kawasaki's website is showing all those parts cancelled (discontinued) except for 14073-1211 which still shows active. Later.


[TABLE="align: center"]
<TBODY>[TR="class: clsGeneral"]
[TD="width: 80%, align: center"]Part Number
help.gif
[/TD]
[TD="width: 20%"]Add to Picklist (Qty): [/TD]
[/TR]
[TR="class: clsGeneral"]
<FORM name=part action=PartInfoDetail.cfm>[TD]<INPUT style="WIDTH: 120px" class=clsGeneral title="Part Number" value=14073-1211 maxLength=20 size=25 name=partnumber> <INPUT title="Show Part Info" border=0 src="res/GoBig.gif" type=image> <INPUT value=112649 type=hidden name=cNodeID> [/TD]
</FORM>[TD]<FORM name=ordering action=PickListAction.cfm?Source=InfoDetail> </FORM>[/TD]
[/TR]
[TR="class: clsGeneral"]
[TD="colspan: 2"]Description: DUCT,CARBURETOR
Package Quantity: 1
Item Status Code: Active



[TABLE="align: center"]
<TBODY>[TR="class: clsGeneral"]
[TD="width: 80%, align: center"]Part Number
help.gif
[/TD]
[TD="width: 20%"]Add to Picklist (Qty): [/TD]
[/TR]
[TR="class: clsGeneral"]
<FORM name=part action=PartInfoDetail.cfm>[TD]<INPUT style="WIDTH: 120px" class=clsGeneral title="Part Number" value=14073-1249 maxLength=20 size=25 name=partnumber> <INPUT title="Show Part Info" border=0 src="res/GoBig.gif" type=image> <INPUT value=112649 type=hidden name=cNodeID> [/TD]
</FORM>[TD]<FORM name=ordering action=PickListAction.cfm?Source=InfoDetail> </FORM>[/TD]
[/TR]
[TR="class: clsGeneral"]
[TD="colspan: 2"]Description: DUCT,LH
Package Quantity: 1
Item Status Code: Canceled



[TABLE="align: center"]
<TBODY>[TR="class: clsGeneral"]
[TD="width: 80%, align: center"]Part Number
help.gif
[/TD]
[TD="width: 20%"]Add to Picklist (Qty): [/TD]
[/TR]
[TR="class: clsGeneral"]
<FORM name=part action=PartInfoDetail.cfm>[TD]<INPUT style="WIDTH: 120px" class=clsGeneral title="Part Number" value=14073-1250 maxLength=20 size=25 name=partnumber> <INPUT title="Show Part Info" border=0 src="res/GoBig.gif" type=image> [/TD]
</FORM>[TD]<FORM name=ordering action=PickListAction.cfm?Source=InfoDetail> </FORM>[/TD]
[/TR]
[TR="class: clsGeneral"]
[TD="colspan: 2"]Description: DUCT,RH
Package Quantity: 1
Item Status Code: Canceled


[TABLE="align: center"]
<TBODY>[TR="class: clsGeneral"]
[TD="width: 80%, align: center"]Part Number
help.gif
[/TD]
[TD="width: 20%"]Add to Picklist (Qty): [/TD]
[/TR]
[TR="class: clsGeneral"]
<FORM name=part action=PartInfoDetail.cfm>[TD]<INPUT style="WIDTH: 120px" class=clsGeneral title="Part Number" value=14073-1251 maxLength=20 size=25 name=partnumber> <INPUT title="Show Part Info" border=0 src="res/GoBig.gif" type=image> [/TD]
</FORM>[TD]<FORM name=ordering action=PickListAction.cfm?Source=InfoDetail> </FORM>[/TD]
[/TR]
[TR="class: clsGeneral"]
[TD="colspan: 2"]Description: DUCT,AIR INTAKE
Package Quantity: 1
Item Status Code: Canceled [/TD]
[/TR]
</TBODY>[/TABLE]
[/TD]
[/TR]
</TBODY>[/TABLE]
[/TD]
[/TR]
</TBODY>[/TABLE]
[/TD]
[/TR]
</TBODY>[/TABLE]
 
I've got the ZL400 parts list open on my spare monitor.

Page E1130-0215 for the airbox and at the top are the bits I think I'm needing. I can only see the number 14073. :(

The picture doesn't even look like what I have on my bike either. :(
 
You must log in or register to reply here.
Back
Top