Zx2r wont start when cold.

[zx2rfan]

the CDI is what the bloke across from me thinks.

[NINJAINOZ]

Sounds like there is not enough fuel getting in (very lean) if there is rust on the plugs & some kind of moisture aswell to cause the rust, How long were the rusty plugs in for?

The iridium plus are good but I would only recommend them for racing or if you want to replace them very often, I have had the tips burn away which left a big gap & caused more problems

The 250 runs the same plugs as my 750 from what I found? CR9E, I was told the CR9EK is a better option, From what I can see they get the spark running horizontal in the chamber & the spark is more exposed & not hidden under the tip, Plus there is to places to arc to>

[zx2rfan]

yeah i have a set of 4 brand new cr9e's or crk9's. will have to check box. only bought the iridium to completely eliminate spark plug issues. they have been in there for nearly a month now. and been cleaned today. im not sure if it was rust on top as it was just like a powder that wiped of.. one was a tad whitish.Will have to buy the cr9ek's then. Would you recommend i wind out the pilot screws half turn each. or just order some oversized jets and seats.
thanks champ

[NINJAINOZ]

the CDI is what the bloke across from me thinks.

Yes it is possible it has a bad connection somewhere or just simply getting old & it has problems
Dry plugs would suggest fuel is not getting in so I would check out the carby's first that way you know for sure it is not running too lean which can cause lots of problems, Just blowing air through the jets is a waste of time usually when there is a build up of gunk in the jets the air will not remove it & people wonder why it still wont run right after blowing air through the jets, Best to take them out & clean or even better to just replace the pilot jets with clean new ones the next size up from stock

Just a matter of eliminating one thing at a time though

http://www.ebay.co.uk/itm/KAWASAKI-ZXR2 ... 415c2649bb

[zx2rfan]

i have replaced that part and the fuses already.

[NINJAINOZ]

At this stage I would leave the mixture screws & just fit new pilot jets & maybe some needles & needle jets if they are worn?

http://2fiftycc.com/index.php?topic=653.0

This is what your pilot jets should look like>
http://2fiftycc.com/index.php?PHPSESSID ... 1621;image

Should be these ones here>
http://www.power-barn.com/servlet/the-1 ... Jet/Detail

Just need to find out the stock pilot jet size & go one up the scale

[NINJAINOZ]

Sort the carby's out & let us know how it goes?

[zx2rfan]

i found a carby rebuild kit on the US ebay, $70 approx, you tell them the bike type and they'll send you an entire kit to suit..
Also when i cleaned my jets i did spray carby cleaner thru them till every hole shot out. so im certain they are clean. i just finish with an air compressor to dry the carby and blow any dust and that out whilst in the putting back together stage. thanks for finding these links for me. appreciate your work.
I have to go to work now i will have to clutch it now -.- hahaha i will work on a few more things tomorrow and wednesday i can organise everything i need.
thankyou will keep you informed.

[NINJAINOZ]

I would not bother with the carby kit/s unless they will supply larger jets then it would be a fairly reasonable price by the sounds of it?

I was going to mention you need to use some jet cleaners or similar (Fine wire) to remove any gunk in the jets, Even carby cleaner may not remove the build up unless they are soaked for ages maybe?

[zx2rfan]

i have just made a big discovery, my bike is missing its 2nd throttle cable. there is a place for it on the carby and throttle. Could this be affecting anything major?

[NINJAINOZ]

No that is just the return cable, It pulls the throttle back to idle if it happens to stick open
The carby's have return springs that do the same thing, No need for the second cable, I have removed the same cable from my bike too

Did you manage to get any other things done?

[zx2rfan]

yeah throughly gone over the carby one again its still out. was considering getting a new cable. have been flat out at work first day off again so ive been fiddling around with it again. about to pull out pilot jets now.

[zx2rfan]

just cleaned the pilot jets with a fine brush and some premium carby cleaner and got a motul motorcycle fuel cleaner to go in the fuel. anything you can suggest trying with the carby while its off?

[zx2rfan]

okay well carby float height- 12.8-13.2 the two barrels in the middle were 13mm 13.2mm, the outside barrels 12.8-12.9mm
pilot jets throughly clean and you were right about some gunk being in there. i checked the fuel seat filters gave em a bit of a soak
fuel filter clean.
mixture screws set at x3 turns each
got a fuel system clean in the tank. will clutch her tomorrow morning still wont start when cold.
starting to lean more towards the starter motor/alternator/ solanoid. ways of ruling them out?
just put another fresh batch of iridium plugs in aswell, old ones weren't burnt out or anything still good but replaced this morning.
fuel seems to run through the fuel line into the carby pretty fast without the tank vacuuming and back.
keep the suggestions coming guys appreciate all your help

[NINJAINOZ]

Is your alternator working OK, I just changed the alternator on my ZXR 750 as it was not quite putting out enough volts like it should have been & it now runs way better, I have read that the ignition system on the ZXR 750 does not run very well with low volts, I thought it was fine because I tried running the motor with a battery charger connected but it did not seem to make a difference, When I fitted a later model ZX7 alternator & went over the wiring it started easier & seems to run & idle much stronger now

Check your battery, Should be around high 12 maybe near 13 volts if you have a good one? When you run the motor you should have around 14 volts