1995 ZR 700...misc issues...

[Billdog350]

My buddy got this machine used with 1500 mi on it. It ran decent for a few hundred miles and then he started wreaking havoc on it....he ripped a motor mount, which messed up most of the engine compartment and controls, and also folded the front suspension in after someone borrowed and hit a tree with it.

Fast forward to today. The machine has been "repaired" by a dealer so the suspension and motor are supposedly fixed. I just went to rejet the thing for the different temperatures and noticed that the dealer never touched the jetting...which was set for 30 degrees and lean as heck...not anywhere near the riding I was doing at -10. Machine ran like crap but the carbs froze up so the motor didn't get leaned out and destroyed....compression is still 150 psi on both cylinders.

Now I have it jetted for 0-20 deg...it runs decent but bogs at WOT once in a while. Plugs seem to be ok...so I don't think its jetting. If I let it idle for a few mins and then nail it again it clears right up for 30 seconds and comes back.....fuel pump maybe?

[cowboyona426]

Hmmm... I'm not sure. You could try the fuel pump, it probably has a filter somewhere that might be plugged. The problem could also be ignition related. Good luck figuring it out! Keep us updated on the results.

[Billdog350]

I've checked spark and plugs, those seem to be ok. Plug wires have been replaced recently. Fuel pump is on order now. Fuel filter was bought today and is in my pocket....I'll keep ya posted.

[Faded]

If I'm reading you right then I would suspect the float level. This should have been checked prior to jetting.

[Billdog350]

I hear a lot about float level...how do you actually set that though? There aren't any sight windows on the carb to adjust anything.

[Faded]

When trying to properly adjust the float level you'll be referencing two different points on the carb. The first point is the flat plane on the body of the carb that the float bowl sits against (sealing lip). You can see this reference point by removing the float bowl and it's gasket or o-ring. After you have removed the float bowl and identified the first point of reference you can now look for the second point. This is located on the floats themselves and is usually a molded seem. Be sure to reference your owner’s manual to verify the reference point on the floats. I have not come across one that is different, but that doesn't mean yours won't be "the one". While thumbing through the manual also look for the height spec in which the float level needs to be adjusted to. If you don't have a manual I suggest you call the service department at your local dealer and ask.

Okay, the height spec you found is the height at which Ref. Point 2, the molded seem (or other point if specified by your manual) needs to be from Ref. Point 1, the sealing lip/plane of the carb body, in order to shut off fuel flow into the float bowl. What I do is grab a wrench that is the same size as the float level spec. I also attach a piece of fuel line over the fuel inlet barb on the body of the carb. To simulate fuel flow I blow into the hose while moving the floats up and down. Now I can place my wrench against the carb body and line it up with Ref. Point 1, the sealing lip. I can manipulate the floats while blowing through the hose and referencing the molded seem on the floats against my wrench to determine exactly at what height the fuel flow will be shut off. If it needs adjustment you can simply bend the tang that sits over the needle (located in the center of the float assembly near the pivot point) in order to obtain the desired float height. You want to set it so that the fuel flow is shut off right at your spec. Adjust in small increments and retest to verify your results. After you’re done you can now reassemble and reinstall your carb.

Also remember that a misadjusted float level will affect jetting. You will most likely need to compensate if you find that your float level was off.

Good luck,
Andrew

[Billdog350]

Thanks for the detail, sounds easy enough. I'll see if my dealer can get me that float level spec so I can check that setting.

[Faded]

Cool, good luck.