Er 5 running problem!

[am3x]

Hi everyone,

I was hoping for a bit of help! I have bought a second hand 1998 er5 and have had problems from the word go! The first problem was this ( https://www.youtube.com/watch?v=OtPhd8zI0tc&feature=plcp ) which has been resolved. ( i think ) I have just passed my test got all my new gear on today weather is fantastic i went for a ride! literally 3 - 4 mins in the bike felt like it was struggling and then eventually lost power and stalled and wont start back up! If i leave the bike for a while, it will start and ride normal for 3 - 4mins then start the cycle all over again! it was not a fun first ride. i was wondering if any of you kind ppl could lend me your knowledge on this one?

Thanks

[Casper]

If that is fuel coming out the air box then no doubt you will have it in the engine. Get an oil filter change done and whip the plugs out. Rag over plug holes and run the starter to pump any fuel out from there.

[am3x]

[Suntan Sid]

Sorry my internet connection is playing up so I can't follow the links for some reason!

Anyway, if your getting fuel in your air filter box, on an ER5, it's definitely a carb problem, you'll have petrol in your oil as well, so you need to change it.
The problem will be combination of dirt in the carbs and an air leak.
Take the tops off the carbs and examine the diaphragms very carefully. The slightest nick in the rubber or if the seal is not sitting correctly in the groove, on top of the carb, this is going to cause problems.
If the diaphragms look the slightest bit dodgy, replace them!
____________________
"Everybody needs money, that's why they call it money!"

[am3x]

[Casper]

Yes get a new filter.

Your air box. Is it like this?

https://i.ebayimg.com/t/GENUINE-KAWASAKI-ER5-ER-5-ER500-A3-1999-AIR-BOX-AIRBOX-/17/!B+,MpwwBGk~$(KGrHqIOKogEy+jC)otJBM+lUvLTrw~~_12.JPG

Look top left. Pipe port and you may have a smaller one at the bottom for a drain.

[am3x]

thats the badger!!! im looking in the haynes cant find anything on this piping (1) is the bottom (2) this is the top so it should be around there but for the life of me i cant find it !

[am3x]

this is the pipe im talking about! damn thing! i hope the service this bike is getting is going to help! im afraid i have bitten more than i can chew! i should of spent the ££ for a bike that works i think! but something inside me doesnt want to be beaten lol

[_Iain_]

Simple explanation.

Take the lid off your toilet.

Flush it and watch what happens when the float comes up.

The water stops flowing.

Now, jam the float down and watch what happens.

The water wont stop - either the overflow will catch it or it'll flood the bathroom.

Same applies to carbs.


When the floats are set at the wrong height, or they stick & the fuel taps on/set on prime, it'll keep filling them up with petrol. After the carbs overflow, they'll fill the airbox up. Then the inlet. Assuming the inlet valve is open, the petrol ends up in the cylinder, filling that up. whereby it gradually drips down the gaps between the rings & fills the crankcase with petrol. (ask me how i know this...)

Hence why bikes have a vac tap. It's a saftey feature to stop shit like that from happening.

Therefore;

Petrol in oil makes it a lot thinner. It wont lubricate aswell. This will make the engine shit bearings, rings etc very quickly if it's not changed out. Also, if theres petrol in the oil then it had to get from the tank to the oil via something. The carbs. Therefore - if it's not been run, and theres petrol in the oil, the carbs ARE at fault. The garage may not have checked the float heights, and it's a right prick of a job to get em spot on as the spring loaded bumper things screw the measurements up.
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[Casper]

That looks like a hole in that picture from the manual. Does the pipe not fit in there?

[Casper]

Ah ha. You may have parts missing. Look at this picture. Click on it to zoom in.

https://www.cmsnl.com/kawasaki-2001-er500-c1-er5_model15068/partslist/79116.html#results

[Suntan Sid]

It's my neighbour who had the same problems, if you want I could take some photos tomorrow to show you where the pipes go.
From memory are there not three pipes that come from the tank, one of which is a reet bastard to connect up!
____________________
"Everybody needs money, that's why they call it money!"

[am3x]

_Iain_ - The carbs have stopped this overflowing after i have gave them to the garage lol but your explanation is very clever and has made me understand the carbs working alot better! do you think the petrol/oil thing could cause the problem im having? irrelevant if the oil needs droping or not?? oh and ............How do you know this? lol

1888 - hmm it seems my airbox doesnt have that hole, but i will double check! im not giving up it will work lol

Thanks for your interest and knowledge, it is very appreciated! i will keep this topic updated on my progress! also a video on youtube hopefully with me riding in what summer we have left!

watch this space

[am3x]

[_Iain_]

Massively. I ended up draining 7-8 litres of oil/fuel mix out of my GS a few weeks ago...ran like utter shit with the fuel in the oil, idled bad, diddnt even take it on the road. Ran for 30 seconds & realised what'd happened!

Floats are either sticking, or have been set wrongly. Or there's a kink/blockage in the line/filter.

The 3-4 mins runtime you're getting is where you're burning all the fuel in the carbs & lines. The downtime is where it's filling back up again.

If floats are sticking closed then they're not allowing the carbs to fill back up with petrol, If the filters blocked then the engines using petrol quicker than it can get back down to the carbs.

You might even find you've got a faulty venting system, so the tanks not letting air back in as it should to replace the fuel. Thus creating a vaccum in the tank and stopping the fuel flow till it repressurises.
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[am3x]

WOW its brilliant it could even work!! lol but honestly that makes perfect sense the question now is how does a slightly dense kid with nothing but a argos home diy kit fix this?? lol i love it when a plan comes together.

[_Iain_]

Tank;

Using the internet to find out where the tank vents, and then finding the relevant pipe on your bike & checking it out for kinks, splits etc.

Fuel in oil;

On the bottom of the engine theres a sump plug. Basicly a bolt, and when you take it out the oils going to piss out everywhere. Chuck a bucket under it and pop that bolt out. Bosh bolt back in when it's finished draining & pour fresh oil in the top. Best googling an ER5 specific guide on google for specific tool sizes.

Sticky floats;

Carbs off, upside down, float bowls off, flip up the right way & blast the shit out of the internals with a can of carb cleaner. Hold right way up till carb cleaner evaporates/drips off.


Keep in mind, everyone started somewhere - usually with shit tools too. Just when you find you need a spanner, go buy a decent set of spanners. When you find you need a socket, go buy a decent socket set etc. Build up tool collection over time. Personally i only moved into a big red chest setup this year. Halfords professional series is reasonably priced, and also comes with a lifetime guaruntee. You break it, they replace it. Although i've not broken anything except impact driver bits yet
____________________
Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340

[am3x]

_Iain_ you're a gentleman and a scholar! i will keep this updated and my YouTube channel hopefully tomorrow is the perfect first ride day lol! i can only pray! take care for now

[Casper]

Look into what Ian is saying about the tank brether. You fuel tap may work but if the tank is not getting air fast enough then the fuel will not flow. Most common fualt to your problem. Tank breather could be a wee hole in the filler neck or a pipe under the tank. Listen for a hiss or take the bike out and if it cuts out open the tank and listen for a whoosh. Whoosh means breather blocked.

[_Iain_]

[am3x]

[karthead]

[am3x]

Hi all,

Just a quick update! i have dropped the oil and changed the oil filter! halfords gave me the wrong one but my local A1 store squared me away! the problem with the bike is FIXED . It was the fuel cap! the air pressure thing was upside down. so when the tank was building up pressure it was closing the rubber seal instead of opening it! i turned it the other way and like magic it worked
I want to thank you all for you help and kindness! i will pass on on knowledge to others and thanks once again.

[Casper]

[am3x]

Hi only me!

A quick one guys! as already discussed i have change my oil and filter! as im looking through the view window when the engine is off i can see the oil! but when its on i cant see it?? is this normal? i hope so lol!