How to remove carburetor on kawasaki zzr-600

To Remove and Install a Carburetor

The carburetor improves the efficiency of an engine by mixing the correct amount of air and fuel. A faulty or dirty carburetor can lead to starting problems, engine hesitation, stalling, rough idle, flooding and poor fuel economy. When replacing a carburetor, information such as the year, make, model, engine size may not be enough to find the replacement carburetor. Information on the correct model number and calibration of the unit can be found on a small metal ID tag on the carburetor.

things you'll need:

  • Base gasket
  • Wrench
  • Small hose clamp
  • Ratchet and socket
  • Needle-nose pliers
  • Cleaning solvent


Carburetor Removal

  • 1

    Disconnect the negative cable from the battery terminal.

  • 2

    Remove the air cleaner assemble, which includes the air box and the intake tubing. Detach the bolts and the hose clamp located at the throttle body assembly, using a wrench or ratchet and socket.

  • 3

    Remove the throttle cable by simply pulling it from the carburetor. If the throttle cable is an eyelet type, use needle-nose pliers and slide it off the arm.

  • 4

    Remove the choke linkage by lifting up the snap ring that connects the choke arm to the carburetor and sliding it off the arm.

  • 5

    Slide the arm out of the carburetor and put it to the side.

  • 6

    Remove the return springs that are connected from the carburetor to the intake manifold by lifting them off their pegs.

  • 7

    Loosen the nut holding the fuel line to the carburetor using a line wrench. Remove the fuel line from the carburetor and push it to the side.

  • 8

    Unbolt the nuts that attach the carburetor to the manifold, using a socket wrench.

  • 9

    Lift the carburetor from the intake manifold. Keep it level to avoid spilling fuel.

Carburetor Installation

  • 1

    Scrape dirt and old gasket material from the area. Clean the carburetor's gasket surface on top of the intake manifold with a strong solvent.

  • 2

    Place the new carburetor gasket over the four studs on top of the engine and place the new carburetor over it.

  • 3

    Tighten the four retaining nuts over the four studs at each corner of the carburetor with a wrench. Tighten the retaining nuts in a criss-cross pattern

  • 4

    Place a new hose clamp at the end of the fuel line. Connect the fuel line to the fuel inlet on the carburetor and connect the throttle cable to the throttle linkage.

  • 5

    Adjust the fuel pressure knobs on the carburetor, following the instructions in the service manual to get the ideal fuel-to-air ratio. Reattach the air cleaner assemble and the cable for the battery terminal.

Tips & Warnings

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