Hi

Firstly major thanks to Bargos, he was so totally clued up and gave me a lot of time. I can't thank you enough.

I had a major oiling up prob and its now cleared thanks to getting a half decent ride. All Carb settings were set to manual standard specs and my bike starts really easily and ticks over smoothly and free revs quite cleanly. When ridden the bike is ok until the throttle is opened more than a little bit where the engine just dies. I rode back from my test area (well local dog walking track) with the choke on and it went quite well so I still think there is a fueling issue here.

I moved the needle clip down a click from middle to next to bottom and this seemed to improve throttle response but its still not right, if I open the throttle very very gently I can build up into the powerband and snatch another gear but it drops off the power very easily.

I have to say it went really well but for some reason seems to be starved of fuel still I might try the bottom clip just for a test but I know this is beginning to indicate there is some other issue somewhere.

Has anyone got a good used carb ???

Jue.

you may already know this,
Pilot is upto 1/3 throttle
needle setting 2/3 throttle
main jet 3/3 throttle

after cleaning carb it can become clogged again if dirt in tank, I always fit an in line filter to prevent this.

Hi

I already been burned twice with crud from the tank, I've now cleaned it and also installed an inline filter.

Good info tho, kinda points to a needle issue it will still be on the pilot when its running well. Then the bad bit is through the needle area then when its up on the powerband it would be main I guess, there is obvious water damage on the needle so I would think that is gonna cause the problems

Uncanny really as most people seem to have their problems with the pilot jet blocking

Jue

you can check top end by doing a plug chop......run bike at max revs proberly in 2nd or 3rd then cut engine. take plug and check colour should be tan if black too rich but most likley white which indicates weak mixture.

oh yes have you checked your power valve is working correctly?

Seems to be, I had the cover off and when ya rev the engine it moved then moved back when the revs drop again.

yeh thats sounds ok to me

Have you replaced the Jets & needle with new ones? possibly will only cost about £20 from Leisure Trail!
If the bike has not been used for some time, the fuel can start to go off! as the fuel goes off, it tends to coat everything with a thin coat of crap, can look like brown varnish! this will partially block the jets & will really muck up your fueling.
I rebuilt a ZXR400 a few years ago, I bought it as a non runner, possibly had not been used for at least 2 years.
When I eventually got it going it ran like crap! I had a Dynojet kit fitted, it was dyno'd before fitting the kit & produced 43BHP after the kit it was giving 65BHP (about average) & ran like a dream.

I've emailed Leisure Trail earlier to ask just that, will prob give them a call tomorra and order all the jets.

For what it will cost its got to be worth doing everything, inc a new needle and bowl seal.

I'm beginning the get excited about it again, the rebuild I did over the early part of winter got to be a bit of a bind especially as I ran out of time and money before even having a ride.
I can see there's not much more to do once I sort this minor prob out I'll have a really nice bike. Just needs to be MOT'd and registered etc I'm ready to roll.

You say you have checked your powervalve , And its ok because you have seen it move? I made the same mistake , Mine moved ok but that was just the exhaust gas causing it to flap about , I had the same sort of problem as you and found one of the cable nipples had broke on the powervalve motor assy and it wasnt working afterall ,The bike felt like a 50cc moped , yet the powervalve looked like it was working ????, Take the cap off the powervalve assy and check you nipples and cables,,Anyways , fixed the cable and Whoohaaaaa,,like sh#t of a shiny shovel

Yeah I did have the cap off and it moves in a robotic fashion, opens when you open the throttle and closes when the RPM's fall back down.

We just found something else that looks important tho, looking closely at the Leisure Trail manual it appears that my engine could well be a Mk3 engine, its certainly a Mk3 head.

Thing is the jetting is completely different for the Mk3 so if thats the case I'm trying to run a Mk3 engine with Mk2 jetting, just not gonna happen.

Any other ways to tell other than the head....

Toad,

It was my pleasure mate.

Sorry but I cant help you to work out whether its a mark3 or not, LT would be able to tell you.

Sounds like you are getting there...

B.