QuestionG'day Mark,
I'm having a lot of trouble with severe flooding on my 1992 Kawazaki ZR1100A (ZEPHYR).
I have had the needle and seats replaced by a professional mechanic who also done all the routine service and tune up like clean carbs, check and reset floats, and synchronise the carbies, new spark plugs etc etc. It didn't make a bit of difference. I rode the bike approx 30-km before it flooded again. I used to get around 220km before switching to reserve but now only get about 130-140km. Now when I start the bike it takes about 10 seconds for the fuel to start pouring out from the overflow.
The only other problem that I can think of is I had a cracked pulse coil (ingnition) cover that used to let in moisture, when I pulled the cover off I found that most parts where corroded (mostly bolts). I was wondering if the pulse coil can be tested as the bike seems to be blowing smoke from the right side muffler which indicates to me that it could be the 1st or 2nd carb that is causing the flooding. Maybe the pulse coil is not working properly. Any thoughts?
Cheers,
Darren. spotted_dog@iprimus.com.au
AnswerHi Darren,
I suspect rust or other particles are getting trapped between the needle valve and seat causing fuel to over fill the float bowls.
Other possible causes that I have experienced:
1) Hairline split in brass float bowl over-flow pipe
2) Improperly adjusted service fuel levels (float heights)
3) Defective floats
4) Worn needle valves and seats
Check fuel tank interior for evidence of rust. The finest rust particles can pass thru fuel filters and collect in float bowls.
Drain fuel from tank & petcock into a gas can via funnel and paper towel to check for rust in tank.
If tank has any evidence of contamination, use Red-Kote or Kreem to seal the tank.
Check airbox and engine oil for evidence of fuel. Fuel often leakes into one or both when over-filling occurs.
Check pulse coils with a simple Ohm and resistance tests. Check service manual for exact test specs.
Respectfully,
Mark Shively
