Question about kawasaki ZZR 400 Motorcycles

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Hi. I have a Kawasaki zzr400. Had the carbs set. Now bike does not start. Sounds like no fuel going through. What might it be.

Posted by Anonymous on

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  • kawasaki Master
  • 43,010 Answers

Hi, Anonymous always check fuel flow first to isolate the problem area otherwise the usual suspects are:
1. Fuel tank empty.
2. Fuel cap or fuel tank not venting properly.
3. Fuel filter clogged with rust or dirt.
4. Fuel valve/petcock not in the on or reserve position.
5. Vacuum line to fuel valve cracked, broken, pinched, or missing*
6. Fuel valve/petcock clogged or diaphragm cracked, cut or torn*
7. Fuel line from the fuel valve to the carburetor or fuel pump clogged, cracked, pinched, bent, broken, or missing.
8. Fuel pump not working*
9. Fuel line touching cylinder or head causing fuel to boil and vapor lock, repair by rerouting and wrapping line with convoluted tubing.
10. Carburetor inlet clogged.
11. Carburetor float or needle and seat stuck.
12. Carburetor not venting properly overflow line or bowl fitting clogged, pinched, or bent.
* If equipped or applicable.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have nice a day.
Zzr 400 carb and starting problems Kawasaki Forums
http://www.zzr-rg.co.uk/forum/viewtopic.php?t=7322
Kawasaki ZXR400 Service Manual Supplement
OEM Parts for Kawasaki
Owner Manuals Service Manuals Kawasaki Vehicles

Posted on Dec 29, 2016

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Posted on Jan 02, 2017

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1 Answer

Howto sync carbs on kawasaki zzr400


best way is to remove the carbs ! get 4 x 4mm drill bits , set carbs on a wide tickover gap on butterflies until you can get the drill bits in the gaps and adjust till all 4 carbs are set the same gaps just slightly touching the butterflie bottom edge and the drill bits trapped between them and carb venturies ! then return the tickover back to shut on the butterflies and look and see if they are all opening and closing together and gaps same after several times ! should be correct if all links are ok ! final tickover setting when fitted on bike to about 600 to 800 rpm ! while the carbs are off you could strip and clean them if you wish ! hope you understand this ! ?? cheers P...

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What are the factory settings for the carbs on a ZZR400. I am having trouble getting the bike to run/idle properly.


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I have a zzr400 but with i start the bike i dont get any revs


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Sounds like the bike is struggling with being too lean.
The choke richens the mixture by increasing the fuel to air ratio
Often these old carbs get worn out and allow air in without going via the air box.
However I would look over the bike and ensure all cables and things are working properly. Ensure all gaskets, gromets and surfaces are seated properly.
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There are adjustments on carbs for low speed air intake (air mixture screw)find out factory settings and reset that mixture.Sounds to me like those adjustments are out of sink.If so the bike will run very bad from idle to about 1/4 throttle then run great from there up to full throttle.this definitly sounds like carb problem.

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It obviously sounds like its being starved for fuel, you said that you replaced the pump and the filter, what about the carbs ? has anyone checked them out ?

If the bike has been sitting over the winter and the carbs were not drained or if the fuel wasn't stablized then you might have some dirty carbs, you can try draining the float bowls and then adding fresh fuel see if that helps, if not you'll likely have to pull your carbs and clean then. Todays fuel doesn't las that long before it goes bad.

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• The first thing to do with ANY engine that has sat for any longer than a couple of months is to dump ALL the fuel in the tank and carb(s). ALL OF IT !! You'll want to refill with some high priced fuel that has fuel system cleaners (Like Chevron with Techron) not becasue you need high-test fuel, but because you need the cleaners. It's ether that or disassemble the carbs and clean out jets you can't find much less see. Your choice. The carb kits alone will cost you about $50 so a tank of high-test is looking pretty good, huh?

• Now the fact that you tried to crank the engine with old fuel has fouled the sparkplugs. All of them. Go buy all new sparkplugs.

• If your bike has a vacuum fuel valve, then you'll also need to set the valve to "Prime".

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1 Answer

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My kawasaki has the same noise, specially when cold, but this should go off when your bike temp goes 1/4.thats my observation with my ZZR400

Feb 25, 2009 | 1997 kawasaki ZZR 400

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Kawasaki ZZR400 Won''t start, Looses power in top Gear


Hi and welcome to FixYa,

Initially, would suggest:
  • a thorough cleanup job on the carbs;
  • inspect, clean the rubber couplings from carbs to intake manifold;
  • inspect tighten coupling clamps;
  • ensure no vacuum leak when re-assembling;
  • inspect, check, ensure air intake box seating to the carbs. Very important, there should be no air leak. All air must pass through the cleaner/filter;
  • check/clean tank, including fuel valve control and built-in fuel filter;
  • use PRIM instead of ON on the fuel valve control.
And the "carborator sleeves" will only slide up when there is sufficient vacuum (engine running) and the throttle is turned.

Good luck and Thank you for using FixYa. Happy Holidays.

Dec 13, 2008 | 1997 kawasaki ZZR 400

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