I have a question and I am really hoping one of you guys/gals might be able to help me out with......
I bought a used 87 ZX6 Ninja that had at least a gallon of coolant in the crankcase (prior owner did a head gasket job and messed something up and also replaced stock petcock and removed all the smog equipment) and now after tearing it down, replacing the gasket, resetting the cams, installing new plugs, testing the coils, and adding new gas, the bike kicks like it wants to start, but just won't do it. My question is... (Actually I have a few.... If there was too much coolant in the crankcase, #1 will the clutch be affected? #2 will the bike not start if the three hoses in the back of the tank are capped off? #3 Without the smog gear, will the valves on the top of the valve cover operate with a hose connected from one to the other? #4 Can anyone thing of anything else I might have missed?
The valves are adjusted, all the wiring is good and connected, all the switches and guages are working, I am baffled. Can you please help?

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Wow!!! it sounds like the dummy that did all of that really screwed it up! I could imagine that having coolant soaking into the clutch discs would probably mess it up after a while. If the vacuum to the petcock valve has been capped of, you won't have any flow to your carbs. I would suggest that you replace all of the emission parts back to OE. If this guy took all that stuff off just hoping it would go faster, he was most likely mistaken. taking off the emission parts will just make it run like crap.

 

Welcome to the forums.....

I have also removed all my smog crap on my ZX10...It is a fairly common practice. If done right, then you will gain some HP, and lose some weight off the bike.... Kawasaki calls it a Kleen system, can't remember what KLEEN stands for. But removing all the smog crap it is called a KLEEN mod.

Yes, with coolant and water sitting in the crankcase, it can mess up the clutch and the lower half bearings.

All three hoses in the back of the tank should not be capped off. It's been a while since I did this, so I don't remember exactly what went where. I have to pull my tank and fairings here in a couple of weeks, IFyou don't get it figured out by then, I will take some pics for ya, and try to help you out on doing it the right way. I have one hose capped off in the back of the tank. I beleive one of the lines in the back of the tank is a vent hose. So try to start the bike with the gas cap open.

Have you done a compression test? Just in case a ring is siezed in there, or there is not too much blow by. If compression is good, are carbs clean and ready to go?

Ususally with that Kleen mod, it requires retrofitting and modifying the airbox. Make sure there are no vacuum leaks. Double check all the hoses and connections, make sure they are all tight. If you can post some pics of the airbox and smog stuff that is left, I can probably remember how they go.

I would guess that who ever did the Kleen, drove the bike afterwards, so I can't see that being your no start problem. I am guessing compression, or carbs....

Gl man, let us know...

 

Thanks for the advice. It's the wierdest thing I have ever seen.......Yesterday after I capped off the vent tube on the left, secured a loose ground, and moved the idle adjustment ****- the bike wanted.......No tried to start but just wouldn't quite fire all the way, so I figured I'd leave it alone on a good note for a change. It's been driving me crazy. Today, I get home and we are right back to nothing. It turns over but it's like there is no spark, I do the spark test- we have spark. I can tell you right now this is no KLEEN deal- Kawi doesn't use duct tape to cover the air box where there is supposed to be a fitting and God only knows what's really been done to this poor bike but I do know- The carbs are fresh, the fuel is less than a week old, the compression is good, new plugs, no blown fuses, I rechecked the timing yesterday and everything was good. The only thing I can think of is maybe the wires aren't right? Firing order is 1423 right? It has dual coil packs and the left pack is going to 1 and 4 and the right pack is going to 2 and 3. The manual is not clear at all and has three different configurations in it and so far none of them work. I honestly don't know how long the coolant sat in it. Any help as far as the plug wires goes would be appreciated and the manual has the emissions diagrams, but all the parts are missing and the manual has color coded hoses- Of course I have no colors.[:@]

 

Oh yeah, I don't know if I said this already, but there is a Pingel fuel valve in the tank too.....Another non OE part. one hose out of it and that feeds right into the carbs if it makes a difference.??

 

Gotta love the duct tape on the air box!! lol lol...It is amazing the things people try to shortcut...

I am not sure of the firing order on your bike... 1423 does not sound like it would be right tho'....Most of the inline fours I thought were fairly standardized, except on the bigbangs.. 1,3,4,2 or 1,4,3,2 ......The coil packs are usually 2-3 on left, and 1-4 on right.

The reason your manual has multiple firing seq, is because there are 4 different options on your bike that year, I believe.. A series and b series. Your vin tag should tell you tho'...

I know Ivans Performance makes a KLEEN mod kit. You might double check to see if they have a kit for your bike. It will come with all the instructions ,and plugs, and etc. That way you can do it the right way.

That firing order just does not sound right that you have. Let me take a look around and I'll see if I can find it for ya...

In the meantime you can always play with it. You might get a back fire or two, but won't hurt anything.

 

Thanks so much for all your help. All my 4 banger cars have been 1342, but I am in the Clymer's manual (came with the bike). It is an A model according to Kawi's website. I am going to doublecheck my wires though and if that's not it, I am pulling the carbs again, maybe I missed something. I think I have the coils packs reversed, I'll have to go down and check it out. Thanks again for everything. I just want to ride it once before summer ends I haven't been able to ride anything since February (I sold my last bike) and the fever is killing me.

 

Ok, well here is the update, we have spark, we have compression, we have everything that an engine needs EXCEPT for gas.
It comes out of the tank with no problem, it fills the filter-again no problem, here's the problem, the fuel will not go into the carbs at all- I have been watchin the level through clear hose and it hasn't dropped AT ALL even though I have been crankin and crankin. I have tried throttle open choke closed, choke half closed, partly closed, open, and closed throttle in all the same formats. I think my carbs are gummed up or it would suck some fuel right?? Now I have had all carbs capped off, check valves open and closed and still no fuel is getting into the carbs.


Any tips ?? Good carb cleaners I can use without damaging any parts? I am gonna drop em off this weekend (probably tomorrow when I get home from work) and go through them again.

The only abnormality visable from outside the carbs is the fitting "t" is farther toward #1 and #2 carb than #3&#4. That shouldn't make a difference should it?

 

you say the fuel won't go any further than just past the filter right? Well it won't unless there is vacuum going to the petcock valve. If you do have vacuum and the gas still won't flow, you have a faulty petcock valve diaphragm.

 

The valve is a Pingel and it's a one way valve- on or off. Open the valve the fuel comes out.......Close it and nothing. Also pulled the carbs off tonight and I bet ya can't guess what I found?? A bunch of CRAP in them........I think I'd better recheck the tank and I am going through the carbs tomorrow to clean and adjust (if needed).
This has been very frustrating but I have to thank everyone for helping. As far as the vacuum goes, perhaps an aftermarket fuel pump like one of my old bikes had??

I will keep you updated as the progress continues and again Thank you all very much