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Old 07-01-2009, 02:03 PM   #1
TurboSetch
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Chapter/Region: AKIC
Location: Palmer,AK
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MANY P3 Import Auto
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Default Anyone here know about Kawasaki 1200 motors?

Looking for someone local to help me track down an issue with my 2004 ZZR-1200. From what I can tell its and inline 4 cyl motor. It seens to have a fuel pump but also has carbs on each cyl (yuck). I think they use this same motor in the the 1200 ninjas as well. Yesterday it started to only run on 2-3 cyls. If I cruise along it will start firing normal but as soon as I put low rpm load on it she will miss change sounds and miss again. Anyone have any ideas where to start...I'm a fuel injection guy and I really don't want to mess with the carbs. I'm hoping to find a bike expert out here.Will trade your time for my time on a suby or what ever.
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Old 07-01-2009, 02:30 PM   #2
aleutdude
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I would check the basics first:fuel filter,vac lines and fuel lines to each carb. Tedious yes but you may find the culprit right off the bat. I've synch'd two carbs on a v twin but to do so on an inline 4 you would need a special tool. Check the plugs as well. Hard to tell if this is an electrical or fuel gremlin from what you describe. I'm no guru and would be willing to help more but with my inlaws here my time off work is full up. If I can check into it I will let you know.
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Old 07-01-2009, 02:37 PM   #3
TurboSetch
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Yeah. I think I need to track down a service manual. The bike was fine the other day but I parked it outside and we had very heavy downpour of rain and on top of that I had to ride it to the gas station on reserve. I though I was just running out of gas at first because thats what it feels like. So I was sucking fuel from the bottom of the tank, wonder if I got some water in there or crud from over the years.




I will pull it apart and check the plugs first. I was just reading that the bike has 2 fuel pumps but can run on 1 not very well. Could have lost a pump maybe.


I wonder how sensitive these bikes are to plugs. I know on my snow machine once a plug is fouled its pretty much over.
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Old 07-01-2009, 03:09 PM   #4
aleutdude
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Japanese inline 4s are pretty tough in general and not too sensitive to plugs but you may be able to tell whats going on by looking at the plugs. From there I'd check the other items mentioned-definitely the fuel filter. You may have just run a bit of water in the system given the circumstances you mentioned. It may be that a tank full of fresh fuel will cure your woes but if that isn't the case then going backward from the plugs is what I'd do. As you go make sure everything is dry. I don't know if you bike has a coil for each plug but it may. If they get wet sometimes it can cause the rough running.
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Old 07-01-2009, 03:21 PM   #5
TurboSetch
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Thanks man, do you happen to have the vacum gauge setup for doing the carb sync? Even if its just a single or double setup. I can still make that work. It looks like the manual says to sync one bank (2 cyls) at a time then put the gauge between the two banks and compare.

I figure if I'm in here I might as well do the full service.
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Old 07-01-2009, 03:35 PM   #6
aleutdude
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I don't have one but I may know someone who does. I will try to get in touch with him. I will post here either way and let you know.
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Old 07-01-2009, 04:15 PM   #7
Gitkrunk
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another suggestion might be to drain the float bowls and see if there is any debris inside, that can cause some problems. Has it been sitting outside or perhaps stored outside?
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Old 07-01-2009, 04:17 PM   #8
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haha i just read your other post saying that it was outside in the rain....float bowls just might be your problem.
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Old 07-01-2009, 05:42 PM   #9
TurboSetch
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Ok..So far I am going to pull plugs inspect or replace. Drain carb bowls. Inspect all lines and filters. Visually inspect electrical. I hope I can find the problem because taking all the plastic off sucks!!

I added some heet yesterday suspecting water in the fuel but after 20 miles no improovement.

I did get down to the bottom of the tank so debris or blocked fuel filters are possible.
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Old 07-01-2009, 09:39 PM   #10
Gitkrunk
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let me know how it goes!
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Old 07-02-2009, 01:30 AM   #11
the parts guy andrew
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hey are u sure your bike is not fuel injected man because i thought those bikes are i have a CBR and i have real bad luck with plugs iv been changing them out once every 6 to 8 months if you ride really hard like i do or reve the bike up alot the plugs will go out sooner also another thing that makes them give out is if you start to ride or reve it up before the bike is warmed up i learned that the hard way. if you cant find out the problem and you need a hand tearing apart the bike let me know ill be more then happy to help you out
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Old 07-02-2009, 12:05 PM   #12
Gitkrunk
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Quote:
Originally Posted by the parts guy andrew View Post
hey are u sure your bike is not fuel injected man because i thought those bikes are i have a CBR and i have real bad luck with plugs iv been changing them out once every 6 to 8 months if you ride really hard like i do or reve the bike up alot the plugs will go out sooner also another thing that makes them give out is if you start to ride or reve it up before the bike is warmed up i learned that the hard way. if you cant find out the problem and you need a hand tearing apart the bike let me know ill be more then happy to help you out
that thing is Carb, a 40mm Keihin if im not mistaken.
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Old 07-02-2009, 03:09 PM   #13
TurboSetch
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Yeah its got 4 carbs and 2 fuel pumps. Last of its kind.

I had to track down the odd tiny spark plugs it uses all over town. I didn't find them in time to start the work yesterday and I have a suby tune to do for a guy. With that out of the way I am going to put the wrench to it tonight.
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Old 07-02-2009, 05:00 PM   #14
aleutdude
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I was unable to track down a carb synch tool and the guy I thought had one did not-sorry. I wanted to let you know and not leave you wondering. I hope you get the bike running right again soon-nice ride!
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Old 07-02-2009, 06:04 PM   #15
TurboSetch
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Hey no problem. I can do it with a single vaccum gauge it just won't be fun. I have some of the tools.

I appreciate your efforts, let me know if I can ever help you with a Suby mods.
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Old 07-05-2009, 03:12 AM   #16
aleutdude
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Preciate it! Just keep us posted on when you get the bike running right again!
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