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Fuel Tank and Carb hook up

This is a discussion on Fuel Tank and Carb hook up within the ZR-7 Maintenance forums, part of the Kawasaki ZR-7 category; This is kind of embarrassing as it seems like it should be basic knowledge, but I do not know which fuel lines go where when ...

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  1. #1
    Up-And Comer carp_5's Avatar
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    Fuel Tank and Carb hook up

    This is kind of embarrassing as it seems like it should be basic knowledge, but I do not know which fuel lines go where when hooking up my tank on my 2000 zr7. I finally have it running (rough) but I do not know for sure which hoses go where. Also, on the microfiche online, it shows that the 2 black plastic "T" fittings on top of the carbs have hoses that run into another T fitting which links it all together. (I broke one T fitting last night while trying to get a hose off and a new one with shipping is like $30, ridiculous!) Is this how it is on yalls bikes? because mine didnt come like that. it just came with a T fitting on each end of the carbs that had hoses attached to them but not linked by another T fitting. I apprecaite all of the help I have received on this site already. I just need a little bit more and I will be ready to ride and know enough to help some others on here as well! Also I need to know where I can get the hoses that I need, because I dont have the right size for the small petcock fitting. Thanks!
    2000 zr7- work in progress

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  3. #2
    Obo
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    Are you talking about the (0verflow and vent) hoses routing from the tank, or the hookup route of the hoses from the petcock to the carbs?
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

  4. #3
    Up-And Comer carp_5's Avatar
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    Embarrassingly enough, I'm talking about both
    2000 zr7- work in progress

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    Rising Star GreyGhost's Avatar
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    Obo
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    That pic only works for Calif emissions models.
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

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    Up-And Comer carp_5's Avatar
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    Thanks for the pic greyghost. Any advice obo? I've looked up the microfiche and I can't seem 2 put all the pieces together, it looked as if the 2 fittings had hoses that met in another fitting which went to the tank but idk. Thanks!
    2000 zr7- work in progress

  8. #7
    Obo
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    Sorry for the delay, but I was waiting for pics and threw my back out on Saturday.
    IMG_3357.jpg
    1 is a cap, 2 is a small vacuum hose on the fuel tank spigot and 3 is an overflow hose that runs back to inside the side panel shot.

    IMG_3359.jpg
    **I noticed I reversed #1 & 2 in this pic. Sorry**
    4 is the main fuel line that runs to a T between the two center carbs.

    IMG_3361.jpg
    5 is a cap, 6 is another overflow hose that runs back to the other side panel and 7 is a vacuum line hose that I think causes the fuel to run from the tank.

    IMG_3363.jpg
    Here's the other end of hose 7 where it goes into the EGR stuff. This is up under the tank by the front of the bike. You should be able to see it if you look up from the throttle side over the exhaust valve cover.

    IMG_3366.jpg
    This is the vent tube for the gas tank. It runs back and down near your shock and exhaust.
    Last edited by Obo; 05-22-13 at 06:22 PM. Reason: noticed numbering error in 2nd photo
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

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    Obo
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    IMG_3368.jpg
    Here's the view of the tank overflow tube that runs down by the shock/exhaust from the tank

    IMG_3369.jpg
    Here's the 2 tubes as they pass by the shock to drain below the swingarm.

    The next two (#3 & 6) are the other end of the overflows from the carbs
    IMG_3370.jpg
    IMG_3371.jpg

    And finally here is the main fuel line (#4) from the petcock. I had to use a mirror to get the pic as I couldnt get the main fuel line off to remove the tank completely. It appears it runs from the petcock down to a T connector, secured by a clip as seen in the pic. There is then a small bit of tube that runs to each carb beside it. I assume looking at the microfische that there is also another small bit of tubing that connects those carbs to the ones beside them, but that isnt visable in the photo. The other black tube like thing in the center is the throttle cable.

    IMG_3372.jpg
    Last edited by Obo; 05-22-13 at 06:24 PM.
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

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    Obo
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    Let me know if I've just confused you more lol
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

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    Up-And Comer carp_5's Avatar
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    NO you actually helped me out a lot! Thank you! and I failed on the pictures again, sorry about that. I had researched it and apparently have it hooked up right but I wasnt sure until looking over your pictures. Except I didnt have the vacuum line hooked to 7 like I need to. Would that cause rough running? I would assume so since it wouldnt operate the vacuum system in the carbs efficiently right? Thank you for the elaborate detail and pics!
    2000 zr7- work in progress

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    Up-And Comer carp_5's Avatar
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    One more question by the way. How do I secure the tank up front??? I have the metal slots that are part of the tank under the rubber stoppers that are connected to the frame, but there is still a lot of play in it. There has to be a bracket that I bolt the tank down to in front and not just in the rear by the seat right???
    2000 zr7- work in progress

  13. #12
    Obo
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    It's just the 2 dampers at the front and the 2 bolts at the rear. Make sure the tank is over the dampers. If there's still lots of play check the dampers to see if they are shot.
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

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    Obo
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    Quote Originally Posted by carp_5 View Post
    NO you actually helped me out a lot! Thank you! and I failed on the pictures again, sorry about that. I had researched it and apparently have it hooked up right but I wasnt sure until looking over your pictures. Except I didnt have the vacuum line hooked to 7 like I need to. Would that cause rough running? I would assume so since it wouldnt operate the vacuum system in the carbs efficiently right? Thank you for the elaborate detail and pics!
    Yes if 7 wasn't hooked up I think it would cause problems. From my understanding it's the vacuum that allows the fuel to run from the petcock.
    I re-edited the pic descriptions as the smaller line that runs from carb 2 to the petcock is actually the vacuum line. I mistakenly said it was the prime line. FYI I also reclarified the two lines on the tank, the rear one is the vent and the one that comes from the front of the tank is the overflow. Guess it helps to look at the diagrams too and not make suppositions based on just looking at the lines.
    --------------------------------------------------------------------------------------------------------------

    2004 Kawasaki ZR-7S

  15. #14
    Up-And Comer carp_5's Avatar
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    Ill have to check on the dampers to make sure I have it seated right on them. Also, I was hoping the vacuum line would solve my rough running problem but, despite what I thought, I did have it hooked up to the number 4 carb's copper nipple and it is still running rough, which im sure has something to do with the exhaust leaks that I will be fixing within a week or so. The help is much appreciated obo, thank you.
    2000 zr7- work in progress

  16. #15
    Newbie bikeknights1011's Avatar
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    Im haveing the same issues on my 01 zr7s. The pic. That has 5,6,7 on mine 5 and 7 is switch will that make a differents?

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