Question about 1999 kawasaki ZR-7

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Fuel in air box?

I recently just purchased a 2000 zr750 I was told i had a float valve sticking. So i took all the carbs off and replaced them. Which helped sooo much. Now i got raw gas leaking out of my air box. but only if i ride it. My guess is float level? How would i go about fixing that?

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  • Anonymous Mar 12, 2009

    so the little pendulium's are just by the air intake side of the carbs? if so how are they alligned to the chamber or adjusted? can this be done with out taking all the carbs off?

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Make sure that all of your little pendulium's that block the gas line when floats are raised are properly aligned in the chamber

Posted on Mar 11, 2009

  • j69bigdaddy Mar 17, 2009

    they are attached to the floats in the bowls of you carb, you should be able to reach these with just removing your seath and gas tank. It is possible to do so while on the bike but it is easier off. Just for comfort reason though.

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A float valve in the carbs is sticking or the float height settings are incorrect or a float has a hole in it.

Might also be worth checking your engine's valve clearances while you are at it as there could be a slight pressure leak causing blowback.

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Usually when you find gasoline in your crankcase it's because your carburator is leaking fuel into the cylinder heads. From there it goes into the cylinders on top of the pistons. Down past the rings into the crankcase. If enough gasoline goes in there, it will go past the sprocket shaft seal and into the primary case as well.

This is normally caused by a bit of trash getting under the float valve in the carburator. But, on a 1996 model, there is supposed to be a vacuum operated petcock. The petcock is supposed to close whenever there is no vacuum on it that is supplied from the intake manifold. Either the petcock has been changed, which is not unusual since the petcocks were quite troublesome, or it is not working properly.

First, you need to clean out the carb. and get any trash out from under the float valve. Remove the carb from the engine. Take the float bowl off the bottom of the carb. Pull the pin out that holds the floats and remove them and the float needle valve. Blow compressed air through the fuel inlet fitting to clean any trash out of the fuel valve seat. Inspect the needle valve for damage, replace if necessary. Reassemble and reinstall the carburator. Check for proper operation prior to starting the engine.

With the carb cleaned, you can install either an aftermarket manual petcock (Pingel) or a Harley petcock for a 1994 or prior model. These are manual petcocks. When you're not riding your bike, turn the petcock to the "OFF" position. Also, install a fuel filter in your fuel line between the tank and the carb. Get one of the good ones with the scintered metal filters in it.

Change your oil and filter. Check your primary oil as well. Change it if contaminated with gasoline. Before you reinstall your air filter, connect the fuel line to the carb and turn the gas on. Closely watch the inside of the carb throat to see if fuel starts to "bubble up" into the throat of the carb. This usually takes a few minutes so be patient. If it does, you need to replace the float valve needle with a new one and check the float setting. If it doesn't "bubble up" you're good to go. Then, don't forget to turn your petcock to the "OFF" position when you quit riding the bike.

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Hi and welcome to FixYa,

Your posted description indicates a carb overflow and that the carbs require a pulldown, disassembly; soaking in carb cleaner, cleaning the jets, vents, holes, ports and the walls of the bowl and inner body for the varnish like gunk of old/stale gasoline specially the fuel inlet valve.

As fuel is fed to the carbs,  the floats in the carb's bowl would rise up and engage the inlet cutoff valve closing the inlet port and therefore no further fuel would flow in. Fuel overflow would then indicate possibly that:
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Good luck and thank you for asking FixYa.

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