Zephyr 550 engine - sounds like shite

[Gracie Jones]

Hey all,

I just bought a Zephyr 550 which is in a bit of a state. Only paid £300 for it, so I don't mind, but wanted some advice.

The engine is the only dodgy bit that is currently beyond my comprehension. It doesn't idle too well and revs stay high after twisting the grip (the grip isn't sticky btw) which I assume is a carb problem - need a bit of a clean no doubt.

The bit I am most worried about is the engine sounds a bit clunky. Not quite the 'bucket of nails' but getting there. Anyone know what common (or uncommon) fault this may be? Is not 'rattly' as such, but at very low revs it sounds like some big bit of metal is a bit loose.

Thanks for any help - happy new year,

Luke

[Gazdaman]

Cam chain tensioner needs adjusting, and the carbs need dismantling and cleaning.

Then see how it goes after that. Fixing these problems is all about doing it in stages.

Gaz

[sickpup]

They all sound like a bucket of nails sir, it's a feature not a fault.

As to the other problems yes the carbs are fubared. The airbox manifolds are also fubared. The inlet manifolds are also possibly, small chance fubared.

Every single Zephyr 550 I've ever seen has fubared carbs regardless of the age and mileage and the airbox manifolds go rock hard about 5 minutes after being registered.

Sorry to seem so grim but most shops won't even touch them with the problems you describe as we know they can't be fixed without spending big money. I've refused to work on two so far this year. Get a second opinion from a shop though as they may feel differently. Would be worth speaking to a Kawasaki dealer as they may know something.

[Gracie Jones]

Lol!

Thanks for the replies chaps. I have a good couple of hundred quid to spend - assuming I do some cleanign of bits myself do you reckon we're talking the right ball-park?

Cheers,

Luke

[Kickstart]

Hi

NRP sell replacement carb diaphragms if they are needed (possible, strip them down and check). Suspect the rubber inlet manifolds are not that cheap and probably perished. The rubbers from the carbs the airbox may also be, as Sickpup said, fubared but they are less likely to cause a problem.

Any bike with the carbs miles out of sync (which is partly the effect of wrecked carb diaphragms and manifolds) will sound like a bag of spanners.

Should be fixable for a few hundred doing the work yourself.

All the best

Keith
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