Huge Fuel Leak after Warm up

Onekallo · July 4th, 2020, 07:12 AM

Hey all. Having some trouble with my bikes here in Canada.

Purchased a pair of used Ninja/ZZR 250 in “ran last year” condition. One is an 05 one is an 06. Neither would start but I am working on them one at a time to get them going.

Tried to start when I got it home, nothing, so I got to work.

Carb cleaning; complete disassembly, soaked in pine sol and water, cleaned all jets and parts as they were very gummed up. I reinstalled everything after adjusting the floats to 17mm (as close as possible anyways)

Reinstalled everything and went to start again.

Fuel in ON position (petcock only has ON - PRI - RES)
Hit started and a increased choke.
Fired up with half choke, ran at 2500rpm and slowly came down as bike warmed up.
Put it into gear and took off down the road. One block away bike was running smooth so I completely removed choke. Shifted to 2nd no problem.
Turned around to come back and noticed there was no throttle response.
Just as I pulled in the driveway the bike quit.
I looked down and fuel is pouring out of the bottom of the bike
Ran into the garage and grabbed some pinch off pliers for the fuel line and the leak stopped shortly after.

I removed the carbs, checked everything over again and it all looks ok. I installed the cleaned out carbs from the 05 and figured I would try that.

Once again started up and ran good, then started to leak fuel like crazy

Is my petcock over flowing into the carbs? (Leaning towards this as it does it with both sets of carbs on the same bike) Or is my needle not fully seating to shut off the fuel?

Any help would be great. Thanks

Artruck · July 4th, 2020, 07:29 AM

Check the seals of your carb float bowls. They would fill when running and leak then stop when the petcock shuts. They get hard over the years and can get splits and flat spots.

I would start the bike up, and let it idle to temp with the bodywork off and watch for where your leak is. That will help you narrow it down.

Onekallo · July 4th, 2020, 07:51 AM

Quote:

Originally Posted by Artruck

Check the seals of your carb float bowls. They would fill when running and leak then stop when the petcock shuts. They get hard over the years and can get splits and flat spots.

I would start the bike up, and let it idle to temp with the bodywork off and watch for where your leak is. That will help you narrow it down.

All float bowl gaskets are new.

Bodywork is off.

Going to try and fire it up again and pinpoint the leak.

DannoXYZ · July 4th, 2020, 11:35 AM

Need to disassemble carbs further. Split them apart to replace fuel-rail O-rings.

Triple Jim · July 4th, 2020, 11:37 AM

A petcock can't supply too much fuel, but the float valves can leak and let too much fuel in. The fuel can then spill out the overflow tubes.

Onekallo · July 4th, 2020, 01:27 PM

Thanks for all the help. Took carbs back apart again, cleaner the seat and made sure float valves were free of debris and clean. Re-installed and so far so good after a few short rides

July 4th, 2020, 07:12 AM	#1
Onekallo ninjette.org member Name: Andrew Location: Courtice, On Join Date: Jul 2020 Motorcycle(s): 06 ZZR-250 - 05 ZZR-250 Posts: 32	Huge Fuel Leak after Warm up Hey all. Having some trouble with my bikes here in Canada. Purchased a pair of used Ninja/ZZR 250 in “ran last year” condition. One is an 05 one is an 06. Neither would start but I am working on them one at a time to get them going. Tried to start when I got it home, nothing, so I got to work. Carb cleaning; complete disassembly, soaked in pine sol and water, cleaned all jets and parts as they were very gummed up. I reinstalled everything after adjusting the floats to 17mm (as close as possible anyways) Reinstalled everything and went to start again. Fuel in ON position (petcock only has ON - PRI - RES) Hit started and a increased choke. Fired up with half choke, ran at 2500rpm and slowly came down as bike warmed up. Put it into gear and took off down the road. One block away bike was running smooth so I completely removed choke. Shifted to 2nd no problem. Turned around to come back and noticed there was no throttle response. Just as I pulled in the driveway the bike quit. I looked down and fuel is pouring out of the bottom of the bike Ran into the garage and grabbed some pinch off pliers for the fuel line and the leak stopped shortly after. I removed the carbs, checked everything over again and it all looks ok. I installed the cleaned out carbs from the 05 and figured I would try that. Once again started up and ran good, then started to leak fuel like crazy Is my petcock over flowing into the carbs? (Leaning towards this as it does it with both sets of carbs on the same bike) Or is my needle not fully seating to shut off the fuel? Any help would be great. Thanks

July 4th, 2020, 01:27 PM	#6
Onekallo ninjette.org member Name: Andrew Location: Courtice, On Join Date: Jul 2020 Motorcycle(s): 06 ZZR-250 - 05 ZZR-250 Posts: 32	Thanks for all the help. Took carbs back apart again, cleaner the seat and made sure float valves were free of debris and clean. Re-installed and so far so good after a few short rides
	1 out of 1 members found this post helpful.

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July 4th, 2020, 07:29 AM	#2
Artruck ninjette.org member Name: Ben Location: Lawrence Join Date: Jul 2018 Motorcycle(s): 2007 ex250 (black), silver 2005 ex250 scrambler, 2003 ex250 donor bike, 2006 kymco people 250 Posts: 73	Check the seals of your carb float bowls. They would fill when running and leak then stop when the petcock shuts. They get hard over the years and can get splits and flat spots. I would start the bike up, and let it idle to temp with the bodywork off and watch for where your leak is. That will help you narrow it down.

July 4th, 2020, 11:35 AM	#4
DannoXYZ ninjette.org certified postwhore Name: AKA JacRyann Location: Mesa, AZ Join Date: Dec 2011 Motorcycle(s): CB125T CBR250R-MC19 CBR250RR-MC22 NSR350R-MC21 VF500F CBR600RR SFV650 VFR750F R1M ST1300PA Valkyrie-F6C Posts: A lot. MOTY - 2018, MOTM - Nov '17	Need to disassemble carbs further. Split them apart to replace fuel-rail O-rings.

July 4th, 2020, 11:37 AM	#5
Triple Jim Guy Who Enjoys Riding Name: Jim Location: North Carolina Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot. MOTM - Oct '18, Aug '17, Aug '16	A petcock can't supply too much fuel, but the float valves can leak and let too much fuel in. The fuel can then spill out the overflow tubes.