Zxr 400 carb float valve o rings

[ZX4R]

Good afternoon. Used to have a account on here but decided to create a new one

I had a 2 year break from biking and my Zxr 400 has sat in the garage.

it wouldn't start as i expected. Drained the tank and refilled. No luck.

So i stripped and cleaned the carbs and rebuilt them.

Iv got the bike running but its running badly.

Its a pain to start and sounds awful. I noticed fuel spilling out the left carb overflow. Researched this and it points towards a sticking float or a worn float valve. All this seemed ok when i rebuilt the carbs.

Took the carbs of the bike and found the float valve filter o rings perished on both carbs 1 and 2.

I am going to order a new seal kit for all 4 carbs.
Question is did i fit these wrong ?
When fitting these previously i pushed them in until the filter sat flush in the carb.
Cant wait to get it running again
Thanks for any help you can offer ?

[Fizzer Thou]

When I needed some obscure and tiny seals for the carbs on my Exup1000 I found the people at Allens Performance more than capable of supplying me with just the parts that I required instead of having to buy a complete and expensive kit.

https://www.allensperformance.co.uk/
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Just talk bikes.What else is there?

Always have a 'Plan B'

[Loui5D]

Should be able to get hold of the seal kit from Cradley Kawasaki, they've had a lot of praise on ZXRworld.

Have you also looked at the battery & the plugs?

[ZX4R]

So today i fitted new float valves and o rings to the carbs.
Built the bike up and it started easy. Let it warm with the choke until it was happy to idle on its own.
Try to open the throttle it only revs to around 5k fully opened, then bogs down and stalls. Restarting the bike is then really difficult and if it does start it will only idle with the throttle open fully.

Im not sure what the problem is. Iv checked for air leaks previously and couldn't find any.

Air filter isn't the best. its not dirty but its very oily.

Spark plugs i havent checked. I have a new set to fit though.

Battery was changed last year and kept on a charger since.

A bit lost as to whats wrong with it.

Anyone throw me some pointers ?

[jaffa90]

When it bogs right down shut OFF the throttle and give it some choke, this will tell you if it`s short of fuel if it stops.

[ZX4R]

Hi thanks for that i tried it and it cuts out using the choke except for on a cold start.

Iv took it all apart again down to removing the carbs and inspecting the carb rubbers. All which seem fine and are tightened properly.

Gone around the carbs making sure everything is tightened up. Put it back together and its running rough but will rev right through now.

I think i have an air leak. I know this bike well and i know when its running poorly just by hearing it. It will idle ok if left alone with a small amount of idle adjustment. The revs also hang for a little after revving.

Im not sure if it needs a good blast as its been sat there at least 2 years.

[jaffa90]

"""""""""Hi thanks for that i tried it and it cuts out using the choke except for on a cold start. """""""""
The carbs seem to be filling up too slow after starting.

[ZX4R]

Hi thanks, i looked this up and i believe this maybe the float height level set wrong ?

Will i need to adjust the service fuel level ??

[neptune8]

Might be a partially blocked fuel filter in fuel tap/ vacuum operated fuel valve.
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Enjoy yourself, its later than you think

[jaffa90]

[ZX4R]

I havent checked the fuel tap. Its not something iv touched before so it could well be partially blocked.

Yes carbs are opening and closing as they should.

[jaffa90]

""""Yes carbs are opening and closing as they should.""""
Are you talking the butterfly valves opening/moving with the throttle cable?

[ZX4R]

[jaffa90]

Overflow, sounds like the needle valve/s are not shutting off the fuel at a certain level.
Also study how C.V. carbs operate / work and then you`ll understand my replies.