zl600 Back to the Shop?

Rhamah

Rhamah

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So I took my zl600 to the shop to have them look over my handiwork (after working on it myself when I could get back home to it) and sync the carbs. When I was pulling in, the radiator dumped and wouldn't suck the coolant back in so I had them look at that too. Ended up requiring a new radiator cap, so no big deal.

Cue 4 weeks later I finally get it back and it runs pretty good. Until I hit the city driving that is. It doesn't like to idle (RPMs too low), so I'll move the idle screw and then at the next red light it will be too high. If I'm in too much stop and go it will dump the coolant to the bottle on the outside and tell me it's too hot, then the revs will shoot up and stick at around 5k even if I put it back into gear and let it bog down, it will just shoot back up again. Also I'm on the RES tank at 75mi, and out of gas completely at around 100. Is that normal?

My question is whether I should bring it back to the mechanic and have them look at it again ($$$) or is this something I may be able to diagnose and fix with my screwdriver and socket set in my apartment parking lot?

Things to know:

-1986 ZL600
- K&N filters
- Jetted Carbs
- California tank on a non-Cali bike
- Tank recently stripped and re-coated
- Petcock recently rebuilt
- Carbs just synced, and cleaned (once by mechanically inclined friend, then later by actual paid mechanic)
- Radiator tested, no leaks
- Usual commute is 2 miles stop and go, then 10mi highway, then 2 miles extreme stop and go. (reverse for ride home)
- Starts pretty good (with choke)
 
When was the last time or has the vacuum tubing/carb boots been checked/replaced? Check for air leaks/vacuum leaks. Is the fan running/working? Sounds like there is still air in the coolant system - probably needs the air bled out of it agian, and again, and again - they can be a pain. Later.
 
When was the last time or has the vacuum tubing/carb boots been checked/replaced?
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Not since I've owned it, unless they did it at the shop.

Check for air leaks/vacuum leaks.
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Got any tips?

Is the fan running/working?
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Definitely. Running good.

Sounds like there is still air in the coolant system - probably needs the air bled out of it agian, and again, and again
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Crap.
 
Also I'm on the RES tank at 75mi, and out of gas completely at around 100. Is that normal?


No, it is not normal for the 600. You should easily be able to go 90 to 100 miles before switching to reserve. Unless you are romping the heck out of it. I would check to see what size jets are in the carbs at present as the wrong size can lean towards poor fuel economy. The reving problem sounds like air or vacuum leaks as Jarney said.
 
On the vacuum stuff - most of the vacuum tubing is super cheap, I would just replace it for piece of mind, but you can visually inspect it, as well as the boots around the carbs - just look for any weathering/cracking/etc. As for the boots around the carbs, I think most guys will use something like wd 40, spray it on and around the boots while the bike is running - if the motor changes it's tune - dies/bogs/revs up, etc, then there is an air leak. Someone will chime in with other ideas/ways to go about this stuff I'm sure. Later.
 
Fixed it guys. The high revving stopped after I put a clamp on the hose from the petcock.

The overheating stopped after I flushed the radiator, and "burped" it. This time I took my time, jiggled the handlebars a bit to get rid if the bubbles. Runs like a dream.
 
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