Carb overflow leaking gas and petcock problems

Hi

I have an 82 kz550 ltd that I bought last summer. Last night I rebuilt the petcock w/ a kit, new diaphragm, and gaskets. That fixed the problem with gas spraying out the side relief valve. Guess the diaphragm was just old and stiff. However now today I actually had a chance to get out on the highway and I hear a ticking sound that increases with rpms. At first I was thinking it was something with the motor, but it sounds like it's coming from the gas tank. I also notice that there is an air bubble in the gas line to the carbs. When I put the petcock on PRI the bubble filled/went away, but when I put it back to ON the bubble came back.

Does this sound like maybe I just didn't do a very good job putting the petcock back together? I'm pretty certain that the "ticking" sound I hear is the diaphragm opening and closing.

Thanx
John

P.S. Since I'm pretty much a newb I'll ask this question here. Would overfilling the oil cause oil to go up the crank case vent into the airbox? Cause I might have done that.

I guess I should point out that this is the stock vacuum operated fuel tap (petcock).

I have no experience with repairing petcocks, however until someone who does comes by I thought I'd give you this link: www.wgcarbs.com//index.php?option=com_co...view&id=17&Itemid=32

I think your bike came with these carbs. Is the vacuum line connected properly?

(Here are links to some other carbs in case I got them wrong: www.wgcarbs.com//index.php?option=com_co...view&id=20&Itemid=37 )

As far as I know everything on this bike is stock except for the 4-1 pipes. The carbs look like the parts diagram

Now I'm starting to think I should just start a thread under the projects category cause I have a feeling I'm going to be needing a bunch of advice. In addition to the "ticking sound" gas is leaking out of the drain/overflow of the carbs. Would that likely be a bad seal on the drain plugs or are the carbs actually overflowing? The carbs are labeled TK. From what I found on wiredgeorge.com they are most likely TK22's.

Thanks for any help

John

Hmm I thought I linked the parts diagram from kawasaki.com but it didn't work. I'll try again in a bit

Could be a malfunction in assembly allowing a small vacuum leak,or the vacuum line maybe hard and cracked.

Yes,an over filled crankcase might blow some oil into the air filter housing.It is easy to check for an over-full condition. If it is, a small hose and some suction will remedy the situation.

HEy thanx Tex. I was trying to figure out how to drain just a bit of oil using the normal method i.e. drain plug. but a siphon would be a lot easier.

Well as far as the gas leaking out of the carbs I think I should just start a new thread in the project area, cause I'm trying to get the carbs out for a good cleaning/inspection and two of the boots are so stiff it seems like they are just part of the airbox. I'm going to have fun getting the airbox out so I can get the carbs out. Any ideas on how to do that with out taking the airbox off? I'm also going to go back through the petcock to make sure I did't get that diaphragm messed up. And I guess I need to check the vacuum line. I know the fuel line should be replaced, it's not cracked but it's as hard as plastic.

Fun, fun. Here I thought I was going to have nothing better to do on this rainy weekend other that drink. Now I have to be productive n shit.

Wow $39.95 per carb kit x4=$160 just to rebuild my carbs on my own. Hmmm Hopefully a good cleaning is all I need.

When you installed the new petcock diaphragm did you put one thin rubber flap on each side of the plastic spacer?

The carbs on the 550 are tough to remove/replace if those boots are hardened ($44/set from Z1E), the airbox will slide rearward a bit. This is a small bolt on each side of the airbox, that when loosened will allow it to slide back about 1/2" or so, but it will still be tough w/out soft boots. It will make you want to drink for sure.

I bet the clicking noise you are hearing is a vacuum leak. Do you have both lines hooked up to the petcock? (gas and vacuum) Also, there are 4 ports on the rubber manifolds between the carbs and motors that need to be plugged. There are vents on the tk22's between 1/2 and 2/3 that need to be clear, otherwise I heard of peoples carbs overflowing badly. These vents are just plastic t's between those carbs with lines on them that run under the seat (at least mine do).

As for the leaking, I'm guessing you have gunk stuck in your float needles/seats. Take the carbs off, clean them very very good. Then take a q-tip, get some metal polish (like mothers) and put the qtip in a drill. Use the drill to polish the brass seat where the float needle sits to clean it up good too.

As far as rebuild kits... I never actually needed to rebuild mine, but replace the float needle yes. They can get a scored little ring around the pointed tip and then not seal. Otherwise these carbs are pretty simply and unless they are really neglected might not need the whole kit.
If you needed new needles, you can get them for 13/each, much better than the whole kit.
www.z1enterprises.com/detail.aspx?ID=2557

BTW, with that ticking and suspected vacuum leak, how does the bike run?

Morius wrote: ...82 kz550 ltd...rebuilt the petcock w/ a kit, new diaphragm, and gaskets...hear a ticking sound that increases with rpms...sounds like it's coming from the gas tank...pretty certain that the "ticking" sound I hear is the diaphragm opening and closing....

80750E wrote: Temporarily clamp off the the line to the vacuum petcock . Does the ticking/tapping stop ?
insert a restriction in the vacuum line (0.025") ....

kopcicle wrote: Coming off #2 carb is a vacuum line to the fuel petcock . Place a restriction in the line with a hole approx 0.025" . Or alternately with the fuel lever in the prime position (straight down) clamp the vacuum line and see if the "ticking" stops .The vacuum petcock gets it's vacuum from the pulse of just one intake and the spring/diaphragm bounce on the outlet seat of the petcock causing the tank to echo and amplify the sound ....

Last two quotes are from > www.kzrider.com/forum/2-engine/444569-va...tment-kz750e1#444612

Good Fortune!

Thanx Patton. I wont be able to do any of that for a while cause I just took the carbs off. I absolutely need to get new boots now cause I pretty much destroyed the old/hard ones.

How can I tell if the needles and jets are stock or after market? I assume that when one of the POs put on the 4-1 pipes that they rejetted the carbs but who knows.

Oh yeah. The bike ran fine after the petcock rebuild. It just made that annoying ticking. I'm going to get new fuel and vacuum lines just in case theres a crack. the ends of the vacuum line were starting to look a little ruff.

Does any one know a good walk-thu for rebuilding a TK carb? All of the one I can find are either keihin or mikuna. Or would the process be pretty much the same?

Thanx for all the help so far.
John