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Discussion Starter #1
Hi guys,

Brand new to this forum however I just got a zzr600 engine today for a project I'm doing and it came with Keihin CVK Carbs and im not sure what everything is. If anyone can help me out with all of the connections (Choke, Fuel, Throttle etc) If someone could help me out with this it would be much appreciated.

Cheers
Joe IMG_5502.JPG
64355
 

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If you want a parts breakdown, look here: 2007 Kawasaki ZZR600 ZX600J Parts - Best OEM Parts Diagram for 2007 Kawasaki ZZR600 ZX600J
That photo is looking at the throttles, and the 3 screws on the linkage between them are for synchronizing them. The black knob left of center sets the idle speed. The cable is connected to the 'choke' (starting enrichment) slide, which is held in place by the screws in the slotted holes; the slots allow it to slide to open the enrichment valves. Looks like you are missing one of those screws. It looks like the throttle cable was attached near the idle control knob, and wrapped around the pulley next to the spring. It appears you have two fuel filters, one on each end of the fuel lines connected between all four carbs.
 

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Discussion Starter #4
If you want a parts breakdown, look here: 2007 Kawasaki ZZR600 ZX600J Parts - Best OEM Parts Diagram for 2007 Kawasaki ZZR600 ZX600J
That photo is looking at the throttles, and the 3 screws on the linkage between them are for synchronizing them. The black knob left of center sets the idle speed. The cable is connected to the 'choke' (starting enrichment) slide, which is held in place by the screws in the slotted holes; the slots allow it to slide to open the enrichment valves. Looks like you are missing one of those screws. It looks like the throttle cable was attached near the idle control knob, and wrapped around the pulley next to the spring. It appears you have two fuel filters, one on each end of the fuel lines connected between all four carbs.
Thankyou very much. I moved what should be the throttle linkage and it only moved the circular flap type things at the front, which was what I thought would've been the choke, and doesn't move the 'plunger' (For lack of a better word) which from my experience with other carbs is the throttle. Is this carb just different or should the 'plunger' move when I rotate what should be the throttle? Also, there's two tubes coming off the carbs at the top, which seem to go between the 1st and 2nd, and a different tube coming off the middle of the 3rd and 4th. Is this overflow or something?

Thanks alot
Joe
 

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Discussion Starter #5
What are you going to do with the engine?
Hoping to get it all working and then put it on my home made off-road go kart. Should be a beast!!! Only got a 125 on there at the moment so should be about 10x power increase!!!
 

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I moved what should be the throttle linkage and it only moved the circular flap type things at the front.
They are CV carbs where the slide and needle are lifted by vacuum.

which was what I thought would've been the choke, and doesn't move the 'plunger'
They don't have a 'choke' in the traditional sense. The cold-start device is a small plunger
on each carb. The choke cable and return spring are visible in your photo.

Also, there's two tubes coming off the carbs at the top
I'm familiar with the CVK40 carbs on my ZZR1100. The 600 seems to have a
very similar arrangement. The tubes at the top are part of the ram-air system.
These increase the relative pressure in the float bowls in tandem with the
pressure increase in the airbox when the bike is moving at high speed.

which seem to go between the 1st and 2nd, and a different tube coming off the middle of the 3rd and 4th. Is this overflow or something?
Most of the plumbing on these carbs is for engine coolant. The carbs are heated
by hot water from the cooling system.
 

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The black caps on top of the carbs (right in this image) are the vacuum chambers for the CV pistons. The higher the airflow, the greater the vacuum formed under the pistons (Bernoulli's principle), which lifts the pistons to keep the air velocity relatively constant through the venturi, half of which is formed by the bottom of the pistons. In carbs that have this piston directly lifted by the throttle cables (VVT), there is no throttle plate, since the piston performs both functions.
 

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Discussion Starter #8
They are CV carbs where the slide and needle are lifted by vacuum.



They don't have a 'choke' in the traditional sense. The cold-start device is a small plunger
on each carb. The choke cable and return spring are visible in your photo.



I'm familiar with the CVK40 carbs on my ZZR1100. The 600 seems to have a
very similar arrangement. The tubes at the top are part of the ram-air system.
These increase the relative pressure in the float bowls in tandem with the
pressure increase in the airbox when the bike is moving at high speed.



Most of the plumbing on these carbs is for engine coolant. The carbs are heated
by hot water from the cooling system.
thank you very much, so would I have to have the ram air hoses connected for it to work properly or would it work perfectly good without?
 

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thank you very much, so would I have to have the ram air hoses connected for it to work properly or would it work perfectly good without?
The ram air hoses that pressurize the fuel bowls have to be in place to match the ram air pressure coming into the air intake/ram air system of the stock Kawasaki induction system.
If you are doing away with ram air induction you will need to use said fuel bowl hoses for venting only, the same as with any other non ram air induction system.

The small black hoses in front of the carburetors, with filter looking things on each end, are for engine coolant to warm the pilot circuits in the carburetors.

S F
 
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