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Carb settings ZZR600E...

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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 21:58 - 01 Jul 2020    Post subject: Carb settings ZZR600E... Reply with quote
Hi gents, having a bit of an issue with my 2003/ZZR600E at the moment, after modifying the airbox to get it to seal it was running fairly rough and on inspection the carb settings were all over the place "so" reverting back to what I think are standard settings, Haynes manual says 11mm/1.5-1.75 out (D series settings) I've set the floats at 11mm but the mixture screws at 2.5 out and she's running a bit rich "but" if I turn the mixture screws in she starts to hang before settling on idle so something's not quite right...

I can't find the correct info concerning mixture screw settings anywhere so my question is does anyone happen to know the standard/factory recommended carb settings for this bike ?...

Any help/info would be muchly appreciated...

Many thanks in advance, Jozzer...
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Nobby the Bastard
Harley Gaydar



Joined: 16 Aug 2013
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PostPosted: 22:31 - 01 Jul 2020    Post subject: Reply with quote
Hanging before settling to idle is symptomatic of an air leak between the carbs and the engine.
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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 22:46 - 01 Jul 2020    Post subject: Reply with quote
Yes, I’ve stripped everything off and inspected for splits/cracks/tears and came up blank, everything got trimmed/replaced/cleaned and rerouted as necessary so now fairly certain everything is good to go buddy...

Don’t suppose you know if a set of D series carbs will work on the E series buddy ?...

I’m currently wondering if the ram air system is the culprit...
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wr6133
World Chat Champion



Joined: 31 Dec 2013
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PostPosted: 08:56 - 02 Jul 2020    Post subject: Reply with quote
Straight out of the Kwak workshop book.

https://live.staticflickr.com/65535/50067319013_a7c2f67206_o.png
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 09:10 - 02 Jul 2020    Post subject: Re: Carb settings ZZR600E... Reply with quote
Jozzer wrote:
after modifying the airbox to get it to seal


So what exactly did you do here? Anything that messes with a ZZR airbox is a recipe for disaster.
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Easy-X
Super Spammer



Joined: 08 Mar 2019
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PostPosted: 10:26 - 02 Jul 2020    Post subject: Reply with quote
Looking at all the differing specs per country you almost have to pity the poor manufacturers. Be curious as to the "track only" jet specifications Smile
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A100man
World Chat Champion



Joined: 19 Aug 2013
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PostPosted: 12:06 - 02 Jul 2020    Post subject: Reply with quote
Easy-X wrote:
Looking at all the differing specs per country you almost have to pity the poor manufacturers. Be curious as to the "track only" jet specifications Smile


and why are Swiss and Californis idle speeds 25% higher than the ROW?

BTW set valve clearances before trying to tune carbs.
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stinkwheel
Bovine Proctologist



Joined: 12 Jul 2004
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PostPosted: 12:14 - 02 Jul 2020    Post subject: Reply with quote
A100man wrote:

and why are Swiss and Californis idle speeds 25% higher than the ROW?

BTW set valve clearances before trying to tune carbs.


At a guess, they have them leaned out so badly for emissions that they won't maintain a stable idle at lower revs.

I think there is a whole load of vapour recirculation stuff on california models too which may need a minimum level of vacuum to function
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.
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wr6133
World Chat Champion



Joined: 31 Dec 2013
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PostPosted: 14:52 - 02 Jul 2020    Post subject: Reply with quote
Read the OP to fast didn't see the airbox bit. These bikes don't respond well to anything altering the airbox, also they will run like shit if those little ram air tubes are not connected properly.

Are the carbs standard or has someone been at them with a drill and jetting kit? These bikes don't respond well to "tuning", especially at the intake end (it's why they make shit street fighters).

Your question about D model carbs. It's the same carbs (Keihin CVK-D36), though as all your jets are different why bother just get a set off an E model, they are more numerous too.

Your intake end should look like this
https://live.staticflickr.com/65535/50068635801_66a6b86b30_o.png


A100man wrote:

and why are Swiss and Californis idle speeds 25% higher than the ROW?


Emissions plumbing screws them up, all sorts of canisters and piping. I think everyone just rips it all out though.
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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 14:58 - 02 Jul 2020    Post subject: Re: Carb settings ZZR600E... Reply with quote
stinkwheel wrote:
Jozzer wrote:
after modifying the airbox to get it to seal


So what exactly did you do here? Anything that messes with a ZZR airbox is a recipe for disaster.


Nothing more than make a couple of plates that help to clamp the box down onto the carbs so that they seal properly...
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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 15:01 - 02 Jul 2020    Post subject: Reply with quote
wr6133 wrote:
Straight out of the Kwak workshop book.

https://live.staticflickr.com/65535/50067319013_a7c2f67206_o.png


Cheers buddy, these are the settings I already have, will try turning the screws in an eighth turn at a time and see how it goes...
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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 15:10 - 02 Jul 2020    Post subject: Reply with quote
wr6133 wrote:
Read the OP to fast didn't see the airbox bit. These bikes don't respond well to anything altering the airbox, also they will run like shit if those little ram air tubes are not connected properly.

Are the carbs standard or has someone been at them with a drill and jetting kit? These bikes don't respond well to "tuning", especially at the intake end (it's why they make shit street fighters).

Your question about D model carbs. It's the same carbs (Keihin CVK-D36), though as all your jets are different why bother just get a set off an E model, they are more numerous too.

Your intake end should look like this
https://live.staticflickr.com/65535/50068635801_66a6b86b30_o.png

As far as I know nothings been altered other than settings which I presume was to try and compensate for the poor sealing airbox, the setup is all standard factory, even the clean air valve is still present...

I asked about the carbs as I happen to have a set of 600-D carbs from an old 92 model I had some years back which I scrapped but kept anything that might be useful, just wondered about fitting them as I know the ram air system can be a total pain in the R’se if it ain’t right...

Basically the same motor barring some subtle differences in valve size and slightly lighter internals so I‘m lead to believe, is that correct ?...


A100man wrote:

and why are Swiss and Californis idle speeds 25% higher than the ROW?


Emissions plumbing screws them up, all sorts of canisters and piping. I think everyone just rips it all out though.
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wr6133
World Chat Champion



Joined: 31 Dec 2013
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PostPosted: 16:20 - 02 Jul 2020    Post subject: Reply with quote
Jozzer wrote:

Basically the same motor barring some subtle differences in valve size and slightly lighter internals so I‘m lead to believe, is that correct ?...


Yes + Ram air, were the main mechanical changes from the D.

If you send me a message with an email address I can send you the manuals. Covers from D - E and all regional variants.
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Jozzer
Two Stroke Sniffer



Joined: 14 Jun 2019
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PostPosted: 18:29 - 02 Jul 2020    Post subject: Reply with quote
wr6133 wrote:
Jozzer wrote:

Basically the same motor barring some subtle differences in valve size and slightly lighter internals so I‘m lead to believe, is that correct ?...


Yes + Ram air, were the main mechanical changes from the D.

If you send me a message with an email address I can send you the manuals. Covers from D - E and all regional variants.


PM sent buddy... Thumbs Up
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Old Thread Alert!

There is a gap of 1 year, 46 days between these two posts...

Domino59
L Plate Warrior



Joined: 18 Aug 2021
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PostPosted: 09:24 - 18 Aug 2021    Post subject: Reply with quote
Old thread, I know. But still somewhat relevant I hope.

I have a D model which was at some point imported from California. The charcoal canister and other smog gear have been disconnected by a previous owner. Should this affect the jetting of the carbs in any way?
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Old Thread Alert!

The last post was made 4 years, 268 days ago. Instead of replying here, would creating a new thread be more useful?
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