Bog/dies under load, now I can't keep her running!

Hey all,

I'm currently working on my 1999 Kawasaki ZX9R. I have just finished a resolving a bad timing issue, oil change, carb cleaning, Dyno Jet Kit, some missing bolts on accecories, and fairing fix. Last night I turn her on and she starts right up, and idles great. She revs well in neutral, just as she should. I hop on to take her for a ride and she bogs. At first I think she must not be warmed up enough, it is cold out, so I nurse her along. The condition does not improve when the bike is fully warmed up, and I cannot get her above 15mph without bogging/stalling, and even slower up hill.

I get her home, and still she idles fine and revs fine in neutral. I leave it to be solved tomorrow.

Today, I try to start her and she has a little trouble starting, but it is cold out. I eventually get her to idle for a minute or two, and she dies. Then it gets to the point where I can only keep her idling if I leaave the choke partially on, and then that seems to be not enough and she dies. Then I can only keep her idling at full choke, and that lasts only a few mintues and she dies.

I pulled the carbs and confirmed that there is fuel in all of the bowls, and it is completely clear and clean when I drain it. I have the carb half apart right now thinking maybe the slides are stuck, but they are perfect. The carb also looks really clean, like it just came from the factory clean. Floats are adjusted properly, no grime anywhere.

I don't want to dive further into a clean carb if I don't have to. I thought maybe it was a fuel pump issue, but if there is fuel in the bowls then is it a fuel issue?

I'd really appreciate the assitance. I have the day off and am going to be at it all day. The bike ran fie with the exception of sluggish performance while using the slow jets, and that was the reason for the cleaning.

Also: I have noticed that the fuel petcock has been modified so that it is a direct on of reserve switch, the diaphram has been modded so I know that it is not locking up.

 

Hey Tink,

It was hard to start and had clogged slow jets before I dove into it. Cleaned the carbs, adjusted the valves (shims), put it all back together. It then ran like this:

YouTube - 1999 ZX9R Engine Noise/Rattle CCT?

Took her apart, discovered that the timing marks did not line up after I had tightened down the cams, but did before (which is a common error I was told with zx9's). Both cams were advanced 1 notch. Fixed that, put her back together, and it reved/idled fine, etc, and that brings us to now. Which was this just before the dying issue:

YouTube - Timing Issue Resolved - ZX9R
I celebrated too soon.

I took the carb apart, it looks extremely clean, carb slides are great, and just put the carbs back on the bike. Now it seems to run fine (idle or rev in neutral) but the airbox is currently off the bike. I'm now trying to see if the issue occurs only with the airbox on the bike.

 

After 7 hours of troubleshooting and removal/installation, I have pinpointed the problem to a kinked fuel line.:hangme:

I had a fuel bottle rigged up and it worked great, but rotated the fuel filter. When I plugged up the tank and installed it the rotated fuel filter kinked. Damnit.

 

Simplest things sometimes!

Glad you are up an running.

 

Thanks guys, just as soon as I think I'm back on the road another issue rears it's ugly head: http://vfrworld.com/forums/mechanic...ing-after-dynojet-kit-install.html#post284044