Trojan441
Senior Member
ZL 400s seem to be the most altered/ butchered machines in UK by would be " Sons of Anarchy" hopefuls, inspired Teenagers, usually making a poor job of things!
Harriminator
Senior Member
Under influence of LSD the colors change (i've heard...).
R. J.
Supporting Member
ZL 500/600 manual. https://www.ebay.com/itm/1986-1987-...867057?hash=item2346dee0f1:g:zbwAAOSwJQxc-1La . GPZ 500/600 service manual. https://www.ebay.com/itm/1985-1986-...a=0&pg=2047675&_trksid=p2047675.c100005.m1851 .
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Trojan441
Senior Member
The Kawasaki Manuals lack practical detail you will need a Haynes for strip down work!
R. J.
Supporting Member
For the older bikes KAW has 2 manuals. Supplement and Service. I've never liked the Haynes and Clymer manuals. I've owned both and they are not as good as the factory SERVICE manuals.
Ed
Senior Member
I hate those aftermarket manuals too. I had one for a 2-stroke once and on the last pages, it gave specs for opening up the ports which was a bonus.
A
Alex Woods
Guest
Thank very much guys much appreciated. I have had a little look into the carbs today. All seemed well/normal. Really hard rubbers to the box and carb rubbers are also absolutely solid. I tried to turn the bike over again and then wiped the plugs out they were quite wet like it has been getting fuel.....I also checked there was a spark and there was so Not sure why it won’t even attempt to fire up unless I spray a bit of easy start in there....however I looked into the carbs and jet/etc and found what looks like a snapped screw. I’m not sure what this one does but it’s the very small one next to the larger one. I have no idea how I would even attempt to remove this and could this be the entire problem? It looks like it’s blocked aswell.
see pictures.
Also a small part that the throttle cable support bracket rests on I found wedged in the choke mechanism has snapped off the back side of the carb so much that when I push it right over it exposes the end of the plunger.
R. J.
Supporting Member
Reversed drill bites work good for getting jets out of carbs. Find a size so that it won't come in contact with the threads of the carb. Set the drill to reverse and gentley/slowly drill into the center of the jet. Most of the time they come out. Which one (part #) is broken. See parts fish. https://www.partzilla.com/catalog/k...86/zl600-eliminator-zl600-a1/carburetor-parts .
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Alex Woods
Guest
Yeah exactly what I was thinking. It’s the smallest one I think. 92064. I think I may be looking at new carb though due to the casing that has snapped off. 
Trojan441
Senior Member
Aftermarket manuals may be light on some technical details. but I personally, find they generally have more advice n' tips on how to carry stuff out, like short cuts when doing a job, etc. than the Kwacker manuals , because my impression is generally, they are aimed @ trained Service personnel, with all the special tools.
As the choke slider mechanism perhaps wears a little, the whole rack need to be lubed regularly, also when putting back the Airbox n' Rubbers & re-setting the cables you have to watch that the "O" ring clamps screw mechanisms, holding the Air-box rubbers, do not tangle with the Choke slider mechanism and Throttle stop screws! Buy some new Air box rubbers it's the only way to make the job do-able!
As the choke slider mechanism perhaps wears a little, the whole rack need to be lubed regularly, also when putting back the Airbox n' Rubbers & re-setting the cables you have to watch that the "O" ring clamps screw mechanisms, holding the Air-box rubbers, do not tangle with the Choke slider mechanism and Throttle stop screws! Buy some new Air box rubbers it's the only way to make the job do-able!
R. J.
Supporting Member
From what I remember we have a member in JAPAN that can get new carb and intake boots/rubbers for the ZL 400. I don't recall who it is.
Harriminator
Senior Member
R. J.
Supporting Member
Yes that is him. If I recall correctly he hooked up TROJAN with a new set of OEM air box boots.
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Alex Woods
Guest
Am I looking at a new carb because of this though guys?
R. J.
Supporting Member
Is that a rail that holds the 4 carbs together or is that the choke slide.
A
Alex Woods
Guest
its th me choke slide. If you look into the centre circle you’ll see the end/pin of the choke valve? I’m not really sure what it’s called the bit that moves left and right (im assuming controls the flow of fuel) as you operate the choke slide.
Harriminator
Senior Member
Harriminator says: feel free to download whatever you like of service manuals:https://pdfmotomanual.com/index.php?r=site/page&view=manuales&order=t&key=K&make=1815&lang=ENG
http://www.manualedereparatie.info/categorii/kawasaki.html
R. J.
Supporting Member
ALEX : Do you have the part that broke off. Which carb is that. # 1 carb is on the left side of the bike as you are sitting on the bike. Here are pics of a set of carbs from a 1987 Kawasaki GPZ 1000. We can use them for a reference. I think the last pic is of the area that is the broken part on your carb. 
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R. J.
Supporting Member
That would be the #3 carb. The broken off part is where the choke plunger sets into. Also the throttle cables mounting stay bracket screws into it. Which is the back side. Most likely that would suck air into that cab. All of the 80s inline 4s use the same choke plunger. https://www.partzilla.com/product/kawasaki/16016-1061?ref=6a46bb584dbfd6ae8112b7a1f6961d0ecb9ec2f3 .
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Ed
Senior Member
Maybe it got broke when someone used an impact driver on them.
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