Kawasaki zzr600, non runner, will it start?, fix, repair, service, carbs

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In this video we service this zzr600 and give it a good clean up. Will it start though?
Thanks to Jake Corb for working on the bike and providing motorcycle parts. If anyone needs things like jets, carb cleaners, brake cleaners, alarms and any motorcycle related parts then please go to eBay and write Jake Corb into the search bar. It's jakecorb in 1 word for ebay or copy the link below.
www.ebay.co.uk/str/carbpartuk
This was a great day, I really enjoyed it.

[@motorcyclerescuer]

If your watching this video please support the channel and subscribe.

[@matthewdove3520]

My uncle has a Suzuki bandit 600s in dark green colour it’s 1998 he got it brand new only done 500 miles been in garage so many years covered lovely bike don’t no why he stopped using it

[@motorcyclerescuer]

Wow that's pretty amazing. Worth polishing that and keeping it.

[@duncanburke4594]

I've got the American equivalent the ZX6 '95, it's the only thing I own. It doesn't run yet but one day I hope to ride it. Good job guys.

[@motorcyclerescuer]

Hi mate, a good carb clean, fresh fuel and a battery should tell you if yours will run or not. Are you in America or the UK? Thanks for watching and subscribing.

[@duncanburke4594]

@@motorcyclerescuer I'm in the uk. I'm confident that I'll get her running with little cost but a fair bit of work.

[@motorcyclerescuer]

@@duncanburke4594 well if you ever want a trip to London I'm sure I could give you a hand. I love hearing bikes come alive after sitting for years.

[@johnandrewservice8598]

Great video guys. I'm going to be buying one of these ZZR's soon.IT has'nt been started in a while. So this has been a good video reminder how to service the bike myself. Thank you for sharing this information. Onelove.

[@motorcyclerescuer]

Thats great news, that's what this channel is all about. As long as your gentle with the carbs you won't need to worry about re syncing them. Good luck with it. Thanks for watching and the comment. Charlie

[@jimbob12382]

What’s going on here? My god!!!! 1. Tank tank off 2. Clean tank & fresh fuel 3 remove carbs strip down & rebuild, You. Could check the plugs for a spark, to see if any are wet, fouled? Instead of just pushing the start button Hoping for the best! The way that petrol tank was slapped on its side on the concrete floor lovely!

[@motorcyclerescuer]

Lol the bike ran beautifully once we were finished and sold to a collector who put it in his museum. So I'm pretty happy with the outcome.

[@stikmannn]

I almost cried seeing that old tank sideways on the concrete 😵😂

[@motorcyclerescuer]

I've not watched this vid for a long time so am unsure what you mean. But I'll take a look tonight. Either way, the bike came out beautifully in the end and went to a collector.

[@deandempsey264]

Nice work lads

[@motorcyclerescuer]

Thanks for watching Dean. Cheers mate

[@dbrhdwk1239]

Well watched your video. My zzr600 has the same symptoms. It won't start. Especially in spring. I think of inspecting the start jet of the carburetor first, then measuring the compression pressure and replacing the piston ring when the pressure is under.

[@motorcyclerescuer]

Yes I would do a good carb clean first and make sure the fuel pump is pumping. A compression test will tell you if the rings are OK or not so we'll worth doing.

[@mattmiles8895]

Nice

[@matthewjackson3034]

Just got myself a slide damaged, hidden away ZZR 600. Less than 10k on it. All the back end is apart at the moment for deep cleaning. Battery flat as, oil looks over full too. Hoping this starts OK once I get round to it.

[@motorcyclerescuer]

Hi Matthew, they are generally pretty solid engines. Depending on how long it's sat there are a few things you can do to help it start. I bet with fresh fuel and carbs cleaned it fires straight up.

[@matthewjackson3034]

@@motorcyclerescuer Hopefully 🙏

[@Snipersight00]

Jake was lucky to come away without any oil on his white trainers lol. You had a good deal with the cash and the ZZR for the Thunderace. Jake Corb didn't bring anything up on ebay by the way.

[@motorcyclerescuer]

Lol he's been out the game for a while, he hasn't worked on a bike for nearly 2 years now so didn't really come prepared. When I search him it says nothing found and then says check for user or something. That's when he comes up. Thanks for watching, I've got another interesting video tomorrow that I'll upload.

[@motorcyclerescuer]

After checking, you have to put it on 1 word. Jakecorb.

[@divviedave1348]

Not a bad days graft. Non running to sounding sweet. Good looking bike too

[@motorcyclerescuer]

@@divviedave1348 hi Nat, Yeh I guess we got lucky again. You never know what your getting. I knew the bike had started before Xmas but didn't run well. It was started around 8 months before that. It needed a good service over all including carb clean and balance and the right amount of oil in as it was way over full. Any luck sourcing yourself a project?

[@CurmudgeonExtraordinaire]

I would check the rear light bulb before chasing a possible wiring problem. Either use a multimeter to check the bulb or just use the 12V leads from a known good battery source to see if it will light up. Use the multimeter to see if there is 12V at the light receptacle, if not, then check the fuse that goes there. If a fuse is blown, then you might have a worn wire that is shorting to ground and that can be a real pain to chase down sometimes when you have to remove a lot of parts on the bike to gain access to the wiring. But, as you have shown in this video, just removing parts so that you can even gain access to the carbs is a pain on this bike -- which is why I end up just taking it to a shop and let them have all the fun. Do they put ethanol in your gasoline over there in the UK? They do here and the carbs will gunk up if you don't run the bike very often. My bikes usually sit up all summer and I only ride them in the "winter" (which is about the temperature of *your* summer). The fuel injected Harley has no problem starting up, but the Kawasaki with carbs will seldom start.

[@motorcyclerescuer]

Yes we have the same problem and they soon want to up the amount in our fuel. Our fuel can go off in 2 months sometimes.

[@CurmudgeonExtraordinaire]

@@motorcyclerescuer -- Or as I like to say, "Putting ethanol in gasoline is a waste of perfectly good corn squeezings"... ("corn sqeezings" is an old term for liquor)

[@motorcyclerescuer]

@@CurmudgeonExtraordinaire ha ha brilliant.

[@CurmudgeonExtraordinaire]

@@motorcyclerescuer -- I suspect that if they put the ethanol in the *drivers*, they would save more petroleum than by diluting the petroleum with it. Of course, you would then have a country of drunk drivers and people might mistake you for Russia... :)

[@relaxingsounds6115]

I just changed the main bearings on one piston cause it got worn out and was making a knock sound and now it just cranks. Any help..?

[@motorcyclerescuer]

Hi mate, what bike is it? The fact that it was knocking could mean that the cylinder has been scored now. Was there any sign of this when you were inside the engine? It's possible that it's low on compression on that cylinder now. Thanks for watching and please subscribe

[@matthewdove3520]

Sorry it’s a 1996 not taxed since 2000

[@motorcyclerescuer]

Sounds great. I bet it will fire up after a little work

[@nonyabeeswax2787]

It seems like you didn't break any rubber seals when you pulled off the top of the carbs. That seems to happen on older bikes. I just purchased a non runner 04 ZZR 600 myself. Same thing really. Tank was rusted so I pulled it and have it soaking in apple cider vinegar for a week or 2. That should should sort it out nicely. As for getting it running, I too made a makeshift petrol container, then drained the carb bowls before starting. I also jumped out the fuel pump to make sure it ran. Sounds like a fish tank pump when running. Fired it up and blew mouse beds out of the exhaust, but it runs. Running rough. I think I need to clean & balance the carbs like you did. How far did you go into the carbs to clean? Did you remove the jets? Thanks

[@motorcyclerescuer]

Hi mate, yes I definitely cleaned all jets and passages aswell as the air/fuel screw and the float valve. The diaphragms on top do split and stretch at times so you would normally just replace them with new ones however if you can save them then thats fine. Don't spray anything onto them as it's a fairly fragile runner. Thanks for watching

[@keveshannaidoo5670]

Built mine up recently

[@QuadcopterAnalyze1980]

hi mate,do you balance of carb 3?also how long do i need to let the engine warm up until i start balancing,Thanks

[@motorcyclerescuer]

Hi mate, ideally it should be warm but it's not a huge issue of its not. You balance carb 1 to 2 then 3 to 4 then carb 2 to 3. This puts them all in sync. Thanks for watching and please subscribe

[@garethtimmins313]

The pipe you say is just overflow 23minutes into vid...pressurises the floats in the carb so I believe.

[@motorcyclerescuer]

No idea mate as it was a long while ago. Definitely got it all back together and running. I think in the next vid I did all the pipes again as one of the coolant pipes was leaking. Thanks for watching and please subscribe

[@freefalling5158]

What is it that you spray into the intake after removing the fuel tank? I am trying to learn basic troubleshooting and stiff like that before picking up my first carb bike

[@motorcyclerescuer]

It's carb cleaner mate, great for cleaning out the carbs. This should be done if a bike has been sitting for around 6 months or more as petrol goes stale.

[@freefalling5158]

​@@motorcyclerescuer Thanks. Is that good enough or do you eventually have to tear it all apart and clean it?

[@motorcyclerescuer]

@@freefalling5158 you always have to clean it from the inside. All the first spray tells you is if the problem is the carbs. If you then find that the engine starts on the spray that tells you that the carbs need a good clean.

[@kwakkers68]

In the Haynes series of books, there's one of electrics, one on fuel, and a couple on workshop techniques - they've all got a red cover (easy to recognise); be a good starting point for you if you're keen to learn. {Get yourself a good torque wrench, and learn how to use it - saves stripping threads, and/or over/under tightening things - you generally need 2 for bikes - a big one for things like spindles, and little one for things which are more delicate}.

[@cheezyrider1111]

I have a 96 zzr600 basically the exact same bike, bought mine without a carb. Can you remember what those hoses were and where they went to and from the carb? Like overflow and vacuum or what? Can’t find any info on it anywhere

[@motorcyclerescuer]

Yes I know most mate. One bigger hole at the bottom of the carbs in the middle is the petrol, then you have 2 the same size on top of the carb but one left and one right, these are over flow and can be left open. If they have any more then these will be cooling hoses and attach to each other to connect all 4 carbs together. Its not to complex.

[@cheezyrider1111]

Thanks for the info I really appreciate it.

[@keveshannaidoo5670]

@@cheezyrider1111 did you start your zzr as yet?

[@cheezyrider1111]

Been working on a lot of other stuff thru the winter this summer or spring I will

[@oldtimehockey7123]

So was it a rusty tank? That would explain the rust in the carb and the inline fuel filter. If so, did you seal the tank? If you addressed that in this or a different vid, then I missed it.

[@motorcyclerescuer]

Hi, I can't remember but I dont think the tank itself was rusty. Just the carbs, so a good carb clean and new filter sorted it out. Thanks for watching and please subscribe

[@oldtimehockey7123]

@@motorcyclerescuer Ok thanks. Great channel btw. Keep up the good work!

[@motorcyclerescuer]

@@oldtimehockey7123 thanks mate, positive feedback means alot. Charlie

[@MrMichaelConstantine]

I just bought this bike yesterday and rode it 30 miles home, its riding quite lumpy, it cut out twice during the journey but started back up quickly. This morning I took it for a ride, it cut out and wouldn't start again for 15 minutes. The front brakes are shuddering and it will not engage the brake light whereas the back brake does. The pass light does not work, and the front wheel does not move freely due to the brakes. I've got so much work to do on this bike but haven't a clue where to start or what to do. Also the fuel guage is not working. Should the reserve tank be off or on? Thanks.

[@motorcyclerescuer]

Wow, it sounds like a mess mate. Not really sure where to start. I would say a good service first, oil, oil filter, air filter and spark plugs. Next I would move to carb clean and balancing. I would flush out all the old fuel and put new in. If the servicing goes well then you will need to service the brake calipers and possibly put new pads in all round. Brake light is a simple switch or a wiring issue. I hope you didn't pay much for yours mate? Thanks for watching and please subscribe

[@MrMichaelConstantine]

@@motorcyclerescuer thank you so much for replying, I took the brakes apart today, removing the pins were hassle, I'm picking up new pads and spark plugs tomorrow. I'm going to work through it methodically and hopefully it will be running good soon. Love the video mate, will happily subscribe.

[@motorcyclerescuer]

@@MrMichaelConstantine thanks buddy. Spark plugs may solve the running issue alone. The rest is niggles that you can do bit by bit once it's running well. Good luck with it and feel free to message me for advice. I've got few mechanics on my Facebook group if you want to join that aswell mate, they can be very helpful. It's motorcycle rescuer and Jake corb.

[@MrMichaelConstantine]

@@motorcyclerescuer thanks mate, I'll let you know how I get on.

[@oldtimehockey7123]

You've probably got this figured out already, but for anyone else, keep it on the main tank, then, then, if you run out of gas, flip to reserve and drive to a gas station. The "reserve" is just a pickup placed a little lower than the main.

[@MiketheM1K3]

Hey have you made a video on how to switch the fuel pump?

[@motorcyclerescuer]

Yes I've got some vids on a fuel pump switch but also it's very simple when you find it. It's 1 connector block and 2 fuel hoses that you just swap across. I would suggest finding your pump first. When you switch your bike on do you hear the pump prime?

[@LeoSkeats]

What fuel can you run the 1993 ZZR E1 600 on please I have one and was thinking of using a external fuel tank and fresh fuel have put new plugs in and taken air box off with easy start and carb cleaner in the carb it turned over briefly but died with revs but all in all what fuel please E what?

[@motorcyclerescuer]

Honestly I would use premium E5 or less. No E10 ideally mate

[@LeoSkeats]

@@motorcyclerescuer would it at least turn over and idle and after a carb clean on unleaded fuel? Or has to be premium?

[@motorcyclerescuer]

It would definitely run, but in the long term the e10 would eat away at the rubbers and plastics in the bike.

[@LeoSkeats]

@@motorcyclerescuer thanks mate perfect!

[@stevencorbo1220]

It's carbureted so the Jets are probably clogged

[@motorcyclerescuer]

To anyone watching, this bike will be available to buy next weekend once we have put it through an mot. This was Jakes build as I sold it to him for the same price I bought it of Lee. Any questions or if anyone is interested in the bike please let me know and I will let Jake know.

[@azariayehezkel9064]

Zzr600? What the year?

[@motorcyclerescuer]

@@azariayehezkel9064 its gone now mate but I believe it was a 1993

[@azariayehezkel9064]

@@motorcyclerescuer Ok

[@matthewellis9885]

MOT expired which is odd. Just got a 1990 ZZR and having to fix a few things

[@motorcyclerescuer]

@@matthewellis9885 oh really, they are fairly straightforward to work on. I found the carb clean easy enough on them.

[@keveshannaidoo5670]

I need a few cosmetic parts for mine. I'm in south Africa do you have an ebay page perhaps?

[@motorcyclerescuer]

This bike is long gone I'm afraid mate.

[@stevencorbo1220]

Dude there's a ram air system in the front of the bike spray the starter fluid in

[@motorcyclerescuer]

It wasn't connected at the time I think plus that wouldn't clean the carbs. They needed to be taken of and cleaned properly as the bike sat a long time. Thanks for watching

[@TheJs12347777]

Also the air filter would get soaked

[@kwakkers68]

The ducts @ the front of a bike are miles too far away from the carbs. It'll evaporate long before it gets anywhere near a carb

[@TE_53349]

come and fix my 1990 zzr 600 haha. i need help with the throttle cables and carbs

[@motorcyclerescuer]

Are you a new subscriber? Some of my old subs come down and work on their bikes. It's much cheaper throwing it into a van then it is getting a local mechanic to do it

[@TE_53349]

@@motorcyclerescuer i am. just seen your video the other day and was curious

[@motorcyclerescuer]

Oh right. But yeh people at times bring bikes that we look at together. It's an option. How far are you from London?

[@TE_53349]

@@motorcyclerescuer quite a while. i live in the north east haha

[@motorcyclerescuer]

That's a shame. Well if you focus on the basics, carb clean, check for spark, you should be ok over all mate.

[@janwoodworth5072]

Hiya dude mike here whats the smallest legal motorcycle number plate you can get, mine needs changing badly cheers mike ;-),

[@motorcyclerescuer]

Hi Mike 9×7 is the standard but I always buy 8×6 and have never been in trouble with the police and it never gets picked up for mot. So you will probably get away with 8×6 but the smallest lagal plate is 9×7 mate. I gave you a small shout out today.

[@janwoodworth5072]

@@motorcyclerescuer yeah i no thank you brother thumbs up to that ;-)

[@CurmudgeonExtraordinaire]

@@motorcyclerescuer -- Those are some humongous license plates you have over there. Looks like they make you strap a billboard to the back of your bike. Here in the US, our plate size is 7"W x 4"H and some people even complain about that being too large and do things like putting it at 90 degrees or bent. One of my bikes is a Harley with hard bags, so the plate size is not particularly offensive on it, but on some the sport bikes, I can see how they might not like it.

[@motorcyclerescuer]

@@CurmudgeonExtraordinaire it's crazy isn't it. Our are 9 by 7 I believe but I normally get away with 8 by 6

[@CurmudgeonExtraordinaire]

@@motorcyclerescuer -- We don't have a choice on license plates. They are manufactured by the government and when you register your bike for the first time, they give you a metal plate. Each state has a different looking plate. It used to be here (Texas) that our plates were stamped so that the letters and numeral were raised, but they've changed it so that the metal plates are now printed flat. It's probably a bit cheaper to do it that way and if you are trying to bend the plate around a contour on a bumper or the rear of a bike, that might have an advantage. The also have a special reflective coating that makes them more visible for the RADAR speed detectors that the cops use. They want to make it easier for them to get your money. Some states require a yearly "safety inspection" which for a motorcycle is basically just a check of your turn signals, brake light, etc. Around here, they figure that if you can pull it into the inspection bay at the garage without running into their equipment, then your brakes must work well enough. Best I remember, it's around $8 per year for the inspection and $54.75 for the yearly registration / license. Iowa, on the other hand, does not have a requirement for yearly inspection and I seem to remember that the yearly registration for motorcycles was only around $13 for a 2002 Kawasaki ZX600-E10 that I own.