Question about kawasaki ZX-9R Motorcycles

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Hi mate im just trying to set my float level's and my manuel is covered in oil after falling in oil drum just need specs please. kindest regards allan

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  • sharon_da620 Aug 04, 2010

    opps so sorry

    1984 zx900 kawasaki

    regards allan

  • sharon_da620 Aug 04, 2010

    1984 zx900 kwaka opps so sorry with keilhn carbs
    regards allan

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You dont say which year/model. Generally 13mm +or- 2mm except for ZX9R-E which is 4mm +or- 2mm(CVRD carbs)

Posted on Aug 02, 2010

  • Rene Rossouw
    Rene Rossouw Aug 04, 2010

    Keihin 34mm carbs. Float height is 17mmm as measured from the float bowl mating surface to the bottom of the float.




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You'll need to first start off by removing your carb. Be sure to clean the surrounding area to the best of your ability to avoid dirt and debris falling into your carb; or worse, your engine. After you've removed your carb I would suggest a thorough cleaning using carb cleaner (or equivalent) and compressed air to ensure that all jets and passageways are spotless. Avoid using wire or other tools to clean orifices of jets; it's all too easy to alter their original designed dimensions.

After your carb is clean you can now set your float level. The picture below will allow you to become familiar with the parts that are responsible for maintaining the correct float level in your carb. There are four basic parts, the floats themselves (part of the float assembly), the float assembly tang, the fuel inlet needle valve, and the fuel inlet valve seat.

floatlevel1.jpg
(Float assembly pivot pin not shown.)


It is always a good idea to remove the float assembly pivot pin (already shown removed) and extract the float assembly and the fuel inlet needle. The fuel inlet needle is a wearable part and over time can deteriorate. A worn fuel inlet needle can contribute to an irregular float level. Most fuel inlet needles consist of an internal spring loaded bumper (which contacts the float assembly tang) and a plastic or Viton (rubber) tip. Inspect the fuel inlet needle tip for wear and/or damage. To give you an idea, Eric Gorr recommends replacing the fuel inlet needle/seat assembly every two years. I've found that the average cost is around $15 for both parts.

floatlevel2.jpg
(Fuel inlet needle shown with Viton (rubber) tip. The Viton is used to isolate the fuel inlet needle from vibration and to create a better seal against the fuel inlet valve seat.)

Now that you've made sure you aren't going to have any issues from worn parts you can reinstall your needle, float assembly and float assembly pivot pin and continue on to set your float level. The float level measurement is taken from the top of the floats (when the carb is positioned upside down) to the gasket surface of the float bowl as illustrated in the next picture. You can use an open-end wrench (sized per your spec), a small metric ruler, or a float level gauge. The tolerance for your float level is usually around +/- 0.50mm.

floatlevel3.jpg


When setting the float level be aware that the spring loaded bumper on the fuel inlet needle valve may have a tendency to compress under the weight of the float assembly which will skew your measurement. Before you obtain your measurement you'll need to make sure that the float assembly tang just barely makes contact with the spring-loaded bumper. Sometimes it is easier to hold the carb body at a 45-degree angle to avoid compressing the spring in the fuel inlet needle.

floatlevel4.jpg


If you find that your measurement does not match your float level spec then you can carefully bend the float assembly tang to achieve your desired measurement. Be sure to recheck your work, and if you feel confident that your float level is spot on then you can reinstall your carb and get back to riding.

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