91 Ninja zx600d Carb adj

ladenblowfish · 07-01-2009

Hey guys, this is my first post. A few days ago I purchased my first bike. Its a 91 Ninja zx600d. The bike is a real pain to get cranked anytime. We've been suspecting the carbs needing cleaning. I poured some b-12 carb cleaner in each carb and let set for a couple hours but it didn't have any effect. The choke has to be opened for several minutes for the bike to stay running. The idle afterwards is extremely low. Where is the idle screw located? I did notice a round plastic star shaped valve under the carbs. Is this what you turn to adjust the idle? Also, at any time, if the bike is idling and you slow turn the throttle the bike dies but it won't if you rev it high. I have a manual ordered but I want the bike running now.

One thing I've noticed, if you open the choke all the way, the choke knob will quickly close to about halfway. Is this normal? Thanks guys

ladenblowfish · 07-01-2009

The bike will always crank w/ the choke all the way open but it will idle at 4000-5000rpms. Is this normal also? I hate asking so many questions for a noob but I just want to find out whats my problem. There is a valve under the gas tank that has two gas line running to it. It has a round knob on it. What is this knob? No more questions for now. Thanks guys. This is a pic of the valve.http://i582.photobucket.com/albums/s...g?t=1246505674

Lawn Masters · 07-02-2009

your symptoms describe a pilot jet problem well.

that valve WAS a petcock originally, and somehow got broken. I'd replace it with an OEM part, pull the carburetors off completely and clean em thoroughly.

pay special attention to the recessed portions with what may look like small screws in them inside the float bowls, those are your pilot jets and the ones giving you trouble.

I can take a picture of one of my totally stripped CVK carbs for you to use as a base line for your bike.

ladenblowfish · 07-02-2009

Thanks for the info. Since I don't have my repair manual yet I'm kinda worried about taking the carbs apart. Can I remove the carbs together as a unit without removing them one by one and having to sync them? So the pilot jets are my problem? I'll tackle them tomorrow. How do I adjust the idle? What about the plastic star shaped valve under the carbs? I tried to take a pic of it put couldn't get a clear shot.

Lawn Masters · 07-02-2009

yes, the carburetors come off as a rack of all 4, and they're connected together. its easiest to just keep them as a set, and worry about the lower sections.

IF you need help, I'll photograph a set of ninja 250 carbs to help clear up whats what in your set. Carb problems are something I know entirely too much about, having messed with them on most of my more recent bikes at LEAST 4 times.

ladenblowfish · 07-02-2009

Awesome. If you could that would be great!

Rob Baker · 07-02-2009

Just wanted to let you guys know that I am following this thread with great interest. I'm having the exact same problems described above on the exact same bike ('91 ZX-6)! Yours wouldn't happen to be Kawasaki Green and black, would it?

Anyhow, I ran some SeaFoam through it yesterday, but it's didn't seem to have any effect.

Being a n00b, I had the same concerns with removing the carbs and having to re-synch them. I'll hopefully get out in the garage today or tomorrow to start the process of cleaning the jets. Those pictures would probably be a big help.

I've got the Clymer manual for the '90-'97 Ninja ZX-6, so if there's anything I can look up for you or help out with, let me know.

I've never worked on the carbs before, so I'll likely be back with some questions of my own.

ladenblowfish · 07-02-2009

I've been outside since this morning and the bike will not start at all even w/ the choke out.

I want this fixed soon. I'm ready to enjoy my new investment. I'm currently trying to figure out how to take off the carbs together. I see some clamps under each carb that holds them each to a rubber boot. Is this what I take loose to remove the carbs?

Lawn Masters · 07-02-2009

you've got it. there are 4 clamps on the engine side, plus 4 more on the airbox side that need to be loosened, then you'll have to make a little effort to pull the carbs of the engine, use a 10mm wrench to loosen the throttle cables, disconnect the choke cable, and you should be free from the motor.
Note those throttle cables may be a PITA to disconnect.

I just found this site through google, and its EXTREMELY in depth, moreso than I would be about it, and accurate. enjoy the info.
Keihin 32CVK Disassembly

ladenblowfish · 07-02-2009

Are these my pilot jet screws?http://i582.photobucket.com/albums/s...g?t=1246556440

These holes were completely clogged on all the carbs.http://i582.photobucket.com/albums/s...g?t=1246556496

ladenblowfish · 07-02-2009

How many turns should I turn the idle screws? I've heard 1 1/4 turns and 3 turns?

Lawn Masters · 07-02-2009

The exterior holes I wouldnt worry much about, no fuel flows outside the carburetors.

yes that picture is your pilot screw, 2.5 turns is the appropriate starting point, and adjust farther in or out depending on how your bike runs. just be sure every carb gets the same number of turns, so you're delivering equal fuel from each carb.

ladenblowfish · 07-02-2009

I removed all the main jets along w/ the idle jets and cleaned them. Do I completely remove the pilot screws clean them, then tighten them until I feel a little resistance. Finally back them out 2 1/2 turns?

ladenblowfish · 07-02-2009

There is one more jet in the center w/ the main and idle jets but how to I remove it? There is no indention to unscrew it.

Lawn Masters · 07-02-2009

The last component that has no indentation or hex head is pressed in and isnt removable.

yes, remove the pilot screws, clean the passages under them then reinstall and screw in until LIGHTLY seated, then 2.5 turns out from there. if those are obstructed, theres not much chance of your bike idling well.

ladenblowfish · 07-02-2009

I've got everything apart and clean. After I get everything together, I'll post back. Crossing my fingers!

ladenblowfish · 07-02-2009

It turns over but will not crank! With and without choke. I set the idle screws to 2 1/2 turns each. Now what. It at least cranked before I started but it run terrible.

Lawn Masters · 07-02-2009

is there fuel going to your carbs? are you sure you've got fuel? good clean plugs and strong blue spark?

ladenblowfish · 07-02-2009

I put in new plugs right after I installed the carbs. It fired up one time and was reving at almost 5,000rpm w/ the choke off. It slowly turned the throttle screw under the carbs down until the idle dropped to around 2500rpm. It idled for a few seconds then just died. Has not cranked since.

ladenblowfish · 07-02-2009

I let it set for about 20 minutes. I went out and it fired right up! Adjusted the throttle screw down a notch and perfect. It idles PERFECT! Not one problem. Took it for a spin and its so much smoother in the lower rpm's. Only thing I see is the exhaust smells like gas really bad. What would cause this?

07-01-2009	#1 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	91 Ninja zx600d Carb adj Hey guys, this is my first post. A few days ago I purchased my first bike. Its a 91 Ninja zx600d. The bike is a real pain to get cranked anytime. We've been suspecting the carbs needing cleaning. I poured some b-12 carb cleaner in each carb and let set for a couple hours but it didn't have any effect. The choke has to be opened for several minutes for the bike to stay running. The idle afterwards is extremely low. Where is the idle screw located? I did notice a round plastic star shaped valve under the carbs. Is this what you turn to adjust the idle? Also, at any time, if the bike is idling and you slow turn the throttle the bike dies but it won't if you rev it high. I have a manual ordered but I want the bike running now. One thing I've noticed, if you open the choke all the way, the choke knob will quickly close to about halfway. Is this normal? Thanks guys

07-02-2009	#3 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	your symptoms describe a pilot jet problem well. that valve WAS a petcock originally, and somehow got broken. I'd replace it with an OEM part, pull the carburetors off completely and clean em thoroughly. pay special attention to the recessed portions with what may look like small screws in them inside the float bowls, those are your pilot jets and the ones giving you trouble. I can take a picture of one of my totally stripped CVK carbs for you to use as a base line for your bike. __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-02-2009	#5 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	yes, the carburetors come off as a rack of all 4, and they're connected together. its easiest to just keep them as a set, and worry about the lower sections. IF you need help, I'll photograph a set of ninja 250 carbs to help clear up whats what in your set. Carb problems are something I know entirely too much about, having messed with them on most of my more recent bikes at LEAST 4 times. __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-02-2009	#7 (permalink)
Rob Baker Newbie Join Date: Jun 2009 Posts: 5	Just wanted to let you guys know that I am following this thread with great interest. I'm having the exact same problems described above on the exact same bike ('91 ZX-6)! Yours wouldn't happen to be Kawasaki Green and black, would it? Anyhow, I ran some SeaFoam through it yesterday, but it's didn't seem to have any effect. Being a n00b, I had the same concerns with removing the carbs and having to re-synch them. I'll hopefully get out in the garage today or tomorrow to start the process of cleaning the jets. Those pictures would probably be a big help. I've got the Clymer manual for the '90-'97 Ninja ZX-6, so if there's anything I can look up for you or help out with, let me know. I've never worked on the carbs before, so I'll likely be back with some questions of my own. __________________ Rob Baker Owner of 1991 Kawasaki Ninja ZX-6 - In poor shape... looking to restore. Rakeback sites

07-02-2009	#9 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	you've got it. there are 4 clamps on the engine side, plus 4 more on the airbox side that need to be loosened, then you'll have to make a little effort to pull the carbs of the engine, use a 10mm wrench to loosen the throttle cables, disconnect the choke cable, and you should be free from the motor. Note those throttle cables may be a PITA to disconnect. I just found this site through google, and its EXTREMELY in depth, moreso than I would be about it, and accurate. enjoy the info. Keihin 32CVK Disassembly __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-01-2009	#2 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	The bike will always crank w/ the choke all the way open but it will idle at 4000-5000rpms. Is this normal also? I hate asking so many questions for a noob but I just want to find out whats my problem. There is a valve under the gas tank that has two gas line running to it. It has a round knob on it. What is this knob? No more questions for now. Thanks guys. This is a pic of the valve.http://i582.photobucket.com/albums/s...g?t=1246505674

07-02-2009	#4 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	Thanks for the info. Since I don't have my repair manual yet I'm kinda worried about taking the carbs apart. Can I remove the carbs together as a unit without removing them one by one and having to sync them? So the pilot jets are my problem? I'll tackle them tomorrow. How do I adjust the idle? What about the plastic star shaped valve under the carbs? I tried to take a pic of it put couldn't get a clear shot.

07-02-2009	#6 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	Awesome. If you could that would be great!

07-02-2009	#8 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	I've been outside since this morning and the bike will not start at all even w/ the choke out. I want this fixed soon. I'm ready to enjoy my new investment. I'm currently trying to figure out how to take off the carbs together. I see some clamps under each carb that holds them each to a rubber boot. Is this what I take loose to remove the carbs?

07-02-2009	#10 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	Are these my pilot jet screws?http://i582.photobucket.com/albums/s...g?t=1246556440 These holes were completely clogged on all the carbs.http://i582.photobucket.com/albums/s...g?t=1246556496

07-02-2009	#11 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	How many turns should I turn the idle screws? I've heard 1 1/4 turns and 3 turns?

07-02-2009	#12 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	The exterior holes I wouldnt worry much about, no fuel flows outside the carburetors. yes that picture is your pilot screw, 2.5 turns is the appropriate starting point, and adjust farther in or out depending on how your bike runs. just be sure every carb gets the same number of turns, so you're delivering equal fuel from each carb. __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-02-2009	#13 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	I removed all the main jets along w/ the idle jets and cleaned them. Do I completely remove the pilot screws clean them, then tighten them until I feel a little resistance. Finally back them out 2 1/2 turns?

07-02-2009	#14 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	There is one more jet in the center w/ the main and idle jets but how to I remove it? There is no indention to unscrew it.

07-02-2009	#15 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	The last component that has no indentation or hex head is pressed in and isnt removable. yes, remove the pilot screws, clean the passages under them then reinstall and screw in until LIGHTLY seated, then 2.5 turns out from there. if those are obstructed, theres not much chance of your bike idling well. __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-02-2009	#16 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	I've got everything apart and clean. After I get everything together, I'll post back. Crossing my fingers!

07-02-2009	#17 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	It turns over but will not crank! With and without choke. I set the idle screws to 2 1/2 turns each. Now what. It at least cranked before I started but it run terrible.

07-02-2009	#18 (permalink)
Lawn Masters hates stupidity BTK Expert Join Date: Mar 2006 Location: New Port Richey FL Posts: 2,108	is there fuel going to your carbs? are you sure you've got fuel? good clean plugs and strong blue spark? __________________ ZedX 1k owner. henceforth The bike shall be Zed.

07-02-2009	#19 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	I put in new plugs right after I installed the carbs. It fired up one time and was reving at almost 5,000rpm w/ the choke off. It slowly turned the throttle screw under the carbs down until the idle dropped to around 2500rpm. It idled for a few seconds then just died. Has not cranked since.

07-02-2009	#20 (permalink)
ladenblowfish Still On The Kickstand Join Date: Jul 2009 Posts: 35	I let it set for about 20 minutes. I went out and it fired right up! Adjusted the throttle screw down a notch and perfect. It idles PERFECT! Not one problem. Took it for a spin and its so much smoother in the lower rpm's. Only thing I see is the exhaust smells like gas really bad. What would cause this?

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