Motorcycle Repair: Carby problem?, vacuum leak, zxr250


Question
Hi, I have just replaced the timing chain on my zxr250 and after putting it all back together(making sure all markers etc lined up) we have it running but have a carby problem now that is baffeling me.
It runns fine but fills the vacume hoses that link between the carb's with fuel then overfules really badly to the point of flodding the cylinders with fuel??
This was not a problem prior to stripping down and we have checked floats needle seats jets etc and havent found any probs.
I havent seen any manuals available for this bike but the carbs are the same for various models of bikes so can you help?

Answer
Brad, that reply was referencing the fuel valve (petcock) for the fuel tank, not the carbs.... if it has a vacuum operated petcock!

Bill
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Brad, first it isn't a Honda.
Next, it isn't listed at CMSNL where they have many microfiche illustrations online.
Then, it wasn't a US model, so there are probably next to none here and I really don't have anything to reference information to....

The only guess that I can make is that the bike has a vacuum operated diaphragm for the fuel valve and that the diaphragm has failed, short-circuiting the fuel back into the intake line. I am going to assume that you put all the hoses back, as they are designed.

On Hondas, usually the diaphragm fails and there is a vacuum leak and no fuel flow to the carbs, but perhaps the design of the Kawasaki part is different and is behaving differently than I would expect.

I have seen your condition happen on Chinese made scooters, but not on motorcycles, so far.

With no reference material, that is all I can offer you, at this time.

Bill "MrHonda" Silver