Need help with my 1986 ZX600

[GarrettSR5]

Lol fair enough. Carbs are at the shop now!

[GarrettSR5]

Shop just called, they said the only real issue was a lot of water in them
And cylinder 1 and 2 bowls were stuck.
I'm so happy right now, I can't wait to install them and see if it runs!

[GarrettSR5]

After some cranking I finally got it running with the freshly cleaned carbs and new plugs

It didn't sound so healthy so I grabbed a temp gun and noticed Cyl 3 wasn't getting 500F+ the other head pipes were, it was around 350. After it had been running a bit it came back up to 500F+ but would then go down and the idle would fluctuate.
I noticed on the right side of the motor there is a small hole and there was water pouring out, any idea what this is for? The hole is on both sides.
I also didn't have the coolant reservior on it but I had coolant in it. It got up to temp and blew a coolant hose



Any ideas fellas? Thanks!

[GPZ600R]

I replied to your PN, but wanted to replay publicaly, as the question to these holes crops up quite often.

Oh a classic, I can shed some light on this for you

Those holes (there is one on each side of the head) are drain holes. The spark plugs sit deep, and if you get water or coolant in there, it cant go anywhere, so the Kawasaki engineers drilled these holes in the side of the head, they are nothing other than drain holes.

What is happening with your bike is this: The thermostat sits above Sparkplug number 3, and it is leaking. It leaks right onto the plug cap and causes a short out, the spark is shorting out to the valve cover and not at the spark plug, so Cyl 3 is now misfiring. Best indication is the cold manifold. As you also mention there is fluid coming out of this hole, the case is clear. Your thermostat seal has blown, or the o-ring at the bottom end of the U-Pipe has blown. Either way, it is coolant you are loosing, drownign the plug and causing the misfire and rough handling, Change the 2 Orings on the U-Pipe and the thermostat housing seal, and the problem will go away. You might have to change the plug cap too, and dry the plug too, if you leave it too long it will rust into place and thats a cow to get out. This is what it looks like if left annatended too long.:



I didn't see the last sentance for some reason. If you blew the coolant hose then it my not be the seals, but the hose, where did it blow ?
Some people do leave the coolant resevoir off (especially after fitting a 4-1 and the original doesnt fit in the belly pan anymore!) but you shouldnt blow a hose so easily.

Regards
Jason

[ol rusty]

- IMPPORTANT !! - If you have in inline fuel filter, throw it away right now. Throw it hard and far!

Jason[/QUOTE]

i had never been told or read not to use an inline fuel filter, or to use one ... a great bit of info ! thanks