Disconnected fuel vacuum pump?!

cartman · Post by **cartman** » Tue Mar 13, 2007 9:34 pm

Hi there!

Great site you guys have here. I've just signed in on your forum. I ride Fireblade myself, but got a sweet L4 for my girlfriend a week ago. Fits her nicely on height and considering the low weight of the bike.

While preparing it for the season the other day I noticed some weird hoses and what seems to be a disconnected fuel vacuum pump of some sort, right above the electrical fuel pump.

Can anyone figure out what this is? In the service manual of both the H and L model it seems as if fuel pump is used on both models. No sign of a vacuum pump, which practically is disconnected. The only hose that is used on this vacuum pump or whatever it is, is the thin one in the bottom of the second pic which ends in a T which can be seen in the top of the second pic or even in the top of the third pic. It has black tape wrapped around it...

Has the engine been replaced at some point? Has something been removed or modified to this bike? Any ideas? I've got the frame and engine numbers if that helps anyone. The frame number fits as an L4 model but can't figure out the engine number on your model list on this forum.

Hope you can figure it out, as I sure as h... can't.

Post by **Northern ANdy** » Tue Mar 13, 2007 9:41 pm

has it got any electrical feeds going to it? if so can you acertain when they are live.

Looks almost like an EGR valve to me but sure it can't be. Hi by the way

RedexRobB · Post by **RedexRobB** » Tue Mar 13, 2007 10:02 pm

yeah that shouldnt be there at all. The T piece there connects to the vacuum pipes that connect the two outer cylinders, these pipes here

If thats the only thing it is connected to you may as well take it out and replace the pipe. Havent a clue why anyone would put that in there

cartman · Post by **cartman** » Tue Mar 13, 2007 10:04 pm

Hi Andy,

No electrical connections at all. I've updated the pics with a red circle around the "thing" that bothers me and don't know what is. Or... the "thing" doesn't bother me... its just that it is not connected to anything other than the vacuum intake manifold maybe. All other hoses are either left open or closed.

I've searched around for info on an EGR valve, and yes it makes sense that it should be it. But doesn't it exist on a ZXR 400 per original build and should be connected? Could'nt find any info on an EGR valve in the manuals...

Thanks for replying so fast!

cartman · Post by **cartman** » Tue Mar 13, 2007 10:18 pm

Hey RobB,

Yeah, I think you're right!! Now I actually found the two vacuum hoses you mention in section 4-2 in the "Engine Top End" manual of the H model. The do actually just connect to one another. They seem to be left open in the L manual, same section in the "Engine Top End"... I will try to remove the EGR valve tomorrow and connect a new hose between the two outer cylinders 1 and 4. This means that the second vacuum hose connects cylinder 2 and 3, correct? Just be sure...

RedexRobB · Post by **RedexRobB** » Tue Mar 13, 2007 10:21 pm

cartman wrote:This means that the second vacuum hose connects cylinder 2 and 3, correct? Just be sure...

Correct mate

Not sure what they are for myself, some sort of balance on pressures for each cylinder, all i know is these are the pipes you need to remove when balancing the carbs.

Hi by the way, welcome to the forum

get yaself over to the 'getting to know you' forum and introduce yaself with some pics of the ZXR.

cartman · Post by **cartman** » Tue Mar 13, 2007 10:28 pm

All right!

Thanks everyone for helping me out on this. Really appreciate it!

I'll take some better pics of her bike once it is assembled again and post it on that other forum. ... if I get a chance before she rides out of the garage.

She's madly in love with this bike and who can blame her...

Post by **Northern ANdy** » Wed Mar 14, 2007 12:30 pm

so what actually is it

cartman · Post by **cartman** » Wed Mar 14, 2007 5:33 pm

Well, Andy.... it beats me. I don't know what the previous owner have been trying to do with this bike.

When I Google around for the EGR valve, it seems like it improves exhaust gasses emissions, lowers the combustion temperature and prevents spark nocking (NOX) as it feeds a part of the hot exhaust gasses back into the intake manifold. It seems as if they tried to improve something but couldn't and then left the valve there with no use.

Post by **Northern ANdy** » Wed Mar 14, 2007 7:26 pm

yerp thats what Exhaust Gas Recyling valves are for, more of a new thing than 94 though. Seems very strange. You'll have to open it up and let us all know if you have time.

Post by **masterofinsanity** » Wed Mar 14, 2007 9:15 pm

gwet it out and post some part numbers there must be some identifying codes on it???

cartman · Post by **cartman** » Mon Apr 02, 2007 9:35 pm

All right guys... sorry for being away for such a long time now. I've been very busy at work and haven't got much time at home.

But now I've got the valve removed and replaced the connection hose between cylinder 1 and 4 with a fresh one... She runs with no problems. In fact I would say that she runs a little bit smoother during idle.

Perfect!!

Sorry I haven't got any pics for you yet, but I have a day off tomorrow and Wednesday. Should have a few minutes there to take some and maybe look into that weird valve.

RedexRobB · Post by **RedexRobB** » Mon Apr 02, 2007 9:56 pm

Nice one mate, glad to hear it.

cartman · Post by **cartman** » Tue Apr 03, 2007 9:55 pm

Fresh pics of the bike released in the "Getting to know you" forum as promised.

BTW: does anyone know where to find a tool set for this bike? Does anyone have a spare set they would sell or to be more specific; I need the steering stem nut wrench (Kawasaki tool #57001-1100) to lower the rear suspension on the bike... Can it be bought somewhere, OEM or a copy/universal tool that works?

Post by **Northern ANdy** » Tue Apr 03, 2007 10:39 pm

hammer and chisel