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Discussion Starter · #1 ·
I have a 96 ZZR600 (E i believe). When keeping the bike moving in any gear at revs below 3000 its very chuggy. Its fine when accelerating and when i'm over 3k. Any suggestions?

Cheers,
Nick
 

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i believe you need to adjust your float hieght.
i think thats what controls your fuel under 3k
i would try to find the stock hieght and go in and reset it.
i dont know a whole lot about carb work, so hopefully some one else here can help.
 

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It could also be chuggy because its low horsepower engine and you are lugging it. Its not a car engine which redlines at 6000 rpm but a bike engine that redlines around 13000 rpm. You drive a car in the middle of the rpm range, which is 3000 and you should ride a bike at the middle also which is 6-7 thousand. It sounds pretty normal what your bike is doing, unless its violently "bucking" then its a problem but if its just pulsing alittle under 3000 then your ok.
 

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Discussion Starter · #4 ·
Cheers guys. I think you may be right about not driving it at low revs. I'm a bit tight on petrol as its so stupidly expensive in the UK! :D
 

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I occasionally ran my '94 ZZR600 as low as 2,000rpm in sixth gear, and it never "chugged". It sounds to me as though your carbs may be out of synch.
 

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When was the last time the carb was cleaned? Friend has 01 ZX6r, that sat for 4 years with gas in it, I cleaned the carbs yellow stuff came oyut bike ran 90% better, his lazy ass still hasn't replaced fuel filter.....to get tip top.
 

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Discussion Starter · #8 ·
I dont know when the carb was cleaned last. I bought the bike about 5 months ago. Is it easy to clean myself? Could it be done in a day using a standard socket set? Or would I need any specialist tools? - Sorry, but I've never had to do anything like this before!! :D
 

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Go buy a clymer and read the manual and go by that. Very explanitory and will help alot. Sometimes the manuals cover a couple different years or models but the info is the same just the picutres may be different.
 

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Be extremely careful when unscrewing float bowls, brass screws strip soooo easy. I ended up using a cordless drill with a phillips tip and set the torque to 10, took the screws out butter! I had an extra set of hands hold the carb still, while I unscrewed.
 

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Good one, Also be carefull with all the little orfices (sp?) dont try to clean them with something like a steel wire. You can use copper wire to clean as it is softer then the carb materials. You dont want to scratch or gouge any of the jets or orfices in the carb as they are made to very specific sizes.
 

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FYI BE careful and don't lose the little o rings that go on top next to needle plunger. Work on nice table don't want to lose anything on floor.
 

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ya, make sure you use good tools too. If you dont at least have something at least as good as craftsman you might want to go and buy a screw driver set of that brand. The cheap stuff just doesnt hold the screw head well and will slip causing a stripped out head or a big hole in whatever your screwdriver slips into. Hand, carbs, leg, HEART!! Ok maybe not that bad but you can injure yourself or mess stuff up with poor tools. Do it right use good name brand tools of at least craftsman.
 
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