Motorcycle Repair: 87 zx600r, haynes manuals, haynes manual


Question
recently bought a 87 ninja (zx600a)the fuel tank was off and some fuel lines and vac lines were off i have a haynes manual but cant seem to find what hoses go where is there a full schemadic somewhere or can you tell me where the fuel lines are suppose to come in to the carbs also going to attempt a rebuild need a complete rebuild kit where can i get one dealer is not a option

Answer
Hi Blake. I know exactly how you are feeling. Unfortunately, I haven't found a good manual that deals with vacuum and evap hose routing myself. BUT... the answer lies in whether your bike is a California emission model or not. Typically, there is only one fuel line that runs from the tank to the carb rack. It usually attaches to the carb rack between the #2 & 3 carbs. You should also have a vacuum line that runs from one of the intake ports to the fuel petcock valve. Most bikes have a hose routing diagram sticker on them. It could be on the underside of the tank, but more often it is located on the airbox. Also, I find the Clymer manuals to be more helpful than the Haynes manuals. The vacuum and evap hose diagrams are usually at the end of the fuel system chapters. The three biggest concerns you are faced with at the moment are getting the fuel line connected, the vacuum line to the petcock (which opens the flow of fuel to the carbs), and the gas tank vent line hose (make sure it is not clogged). By getting these three things sorted out, you should be able to get the bike started. When I need parts and can't go thru the dealer, I usually deal with either BikeBandit.com or Temeculamotorsports.com. Check these sites for rebuild kits. Good Luck Blake!!!