1991 600R refurbish

idmtchris · May 20, 2007

I just picked up a 91 600R project bike. Pictures will follow very soon. The bike was running about a year ago, when the carbs started having problems. I picked the bike up for $200. Frame is str8 and it does not leak any oil. All I know for sure right now is that carb three leaks fuel as soon as you open the fuel valve. I also know that the bike was full of fuel before being put on blocks. I will also need to replace or repair much of the plastic because of cracks, scraps and missing tabs.

I figure I will use this thread for posting questions and looking for parts. So if anyone has any advice before I start ripping this thing apart feel free to post it.

BTW I am no mechanic so this will be a huge learning project as well. I will post pics as soon as I get them off my camera.

idmtchris · May 20, 2007

Question #1

ok question #1

I removed the carbs pretty easily and I found that the fuel inlet nibble (i think that's what the are) was capped off. Anyone know why this would be?

gpzrider · May 23, 2007

Are you sure it's the fuel inlet and not a vacuum port? If the fuel inlet is capped off, there would be no way for a carb to leak when the valve is opened.

idmtchris · May 23, 2007

No I am not absolutly sure. Each of the four carbs a a nibble all of them were connected to a hose except for carb three. Does each carb have a vacuum and on inlet port?

gpzrider · May 23, 2007

Sounds like a vacuum port. In a typical Kawasaki carb set up from this time period, only three are used. 2 T together and go to the emissions, one supplies vacuum to the petcock, and one is capped off. These are on the top rear of the carbs towards the cylinders.
There is only 1 inlet port that supplies fuel to all four carbs. It should be a slightly larger hose that connects on the airbox side of the carbs between the 2nd and 3rd carbs.

idmtchris · May 23, 2007

Your correct thanks.

dropdfocus · Jul 4, 2007

Yes, my '80 KZ750 is the same exact way. 3 used, one capped off. 2 T off and one supplies the petcock.

Kawasaki ZX600r · Jul 4, 2007

Mine has 2 capped off ( I removed my emissions junk) and 2 T and go to the fuel valve.

600Rider · Jul 27, 2007

Kawasaki ZX600r said:
Mine has 2 capped off ( I removed my emissions junk) and 2 T and go to the fuel valve.

(Back from the dead)

How'd ya do that?

Kawasaki ZX600r · Jul 27, 2007

I bought a plastic T and hooked the two middle ones together and ran them to the fuel valve. I took rubber plugs and pluged them on the two outer ones. Or, you could T 1&2 and 3&4 and then T the two groups and run all four to the fuel valve.

1991 600R refurbish

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