Filed Under (Yamaha) by admin on 18-01-2012
remove seat and gas tank. Make sure fuel petcock is in “off” position. 2. Remove throttle cable paying close attention to routing, as the new cable (s) will need too be routed the same. 3. Remove stock carburetor and stock throttle housing. Stuff a clean, dry rag into manifold to keep debris out of motor. 4. Remove stock air box. 5. Remove choke cable from handlebars. 6. Remove carb vent line from bike. Carburetor installation 1. Carefully trim the rubber alignment tab off of the face of the manifold with a razor blade or side cutters. 2. Remove the hex pipe plug from the carb cap using a 11mm or 7/16 wrench. Do not discard plug, as it will be needed later. Install the metering adjustment tool included in the hardware kit. Do not over-tighten as damage may occur to cap. 3. Attach fuel line to carburetor and secure with clamp. 4. Install remote idle cable into tab on top of carburetor. See main manual for this step. NOTE: Nut must be removed from cable before installation 5. Place carburetor into manifold
Filed Under (KTM) by admin on 12-11-2010
Carburetor adjustment Basic information about the original carburetor setting The original carburetor setting was adapted for an altitude of approx. 500 meters (1600 ft.) above sea level, and the ambient temperature of approx. 20°C (68°F), mainly for off-road use and central European premium-grade fuel (ROZ 95). Mixing ratio 2-stroke motor oil : super fuel 1:40 . Basic information of changing the carburetor setting Always start out from the original carburetor setting. Essential requirements are a clean air filter system, air-tight exhaust system and an intact carburetor. Experience has shown that adjusting the main jet, the idling jet and the jet needle is sufficient and that changes of other parts of the carburetor will not greatly affect engine performance. RULE OF THUMB: high altitude or high temperatures choose leaner carburetor adjustment low altitude or low temperatures choose richer carburetor adjustment * WARNING * -ONLYUSE PREMIUM – GRADE GASOLINE ROZ 95 MIXED WITH HIGH – GRADE TWO – STROKE ENGINE OIL . OTHER TYPES OF GASOLINE CAN CAUSE ENGINE FAILURE , AND USE OF SAME WILL VOID YOUR WARRANTY . -ONLYUSE HIGH – GRADE 2- STROKE ENGINE OIL OF KNOWN BRANDS ( I . E .SHELL ADVANCE RACING X). -NOTENOUGH OIL OR LOW – GRADE OILCAN CAUSE EROSION OF THE PISTON . USING TOO MUCH OIL , THE ENGINE CAN START SMOKING AND FOUL THE SPARKPLUG . -INTHE CASE OFA LEANER ADJUSTMENT OF THE CARBURETOR PROCEED CAUTIOUSLY . ALWAYSREDUCETHEJETSIZEINSTEPSOFONENUMBERTOAVOID OVERHEATING AND PISTON SEIZURE . NOTE: If despite a changed adjustment the engine does not run properly, look for mechanical faults and check the ignition system. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 1000 hours of using. Idling range – A Operation with closed throttle valve. This range is influenced by the idle adjusting screw 1 . Only make adjustments when the engine is hot. The idling speed can be changed by turning the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters and smokes when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum part-throttle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. If the engine runs on a four-stroke cycle or with reduced power when it is accelerated with the throttle partly open, the jet needle must be lowered by one notch. If then the engine pings, especially when accelerating under full power at maximum engine revs, the jet needle should be raised. If these faults should occur at the lower end of the part throttle range at a four-stroke running, make the idling range leaner; if the engine pings, adjust the idling range richer
Filed Under (Honda) by admin on 17-12-2011
K&L CARBURETOR ADJUSTMENT WRENCHES These tools use tough and accurate bevel gear actuation instead of cable for professional use. The aluminum handle includes index marks for accurate tuning. Sold each. Three types available: 35-9653 Slot-type Pilot Screw Adjustment Wrench for Kawasaki/Suzuki/Yamaha 35-9658 Slot-type Pilot Screw Adjustment Wrench with longer tip for Kawasaki/Suzuki/Yamaha 35-9650 D-type Keihin Pilot Screw Adjustment Wrench for Honda 90-DEGREE 1/4″ HEX DRIVER This gear driven, 1/4″ hex driver set is made of high-grade aluminum and stainless steel. Strongest tool of it’s type on the market. Designed for use on hard-to-reach pilot air screws on inline fours. Can be used with any 1/4″ or 6mm hex bits. 35-7820 90-Degree 1/4″ Hex Driver Set: Includes straight slot, phillips, d-shape pilot screw bit, 6mm hex jet bit & 1/4″ – hex – 1/4″ drive bit. FCR CARB TOOL Set includes three bits – 6mm hex for main jets, long reach straight slot for pilot jets and 3mm allen for float bowl removal. Longer bits make this set ideal for reaching into recessed cavities when adjusting Keihin FCR carburetors. Sold as a set. 35-7978 FCR Carb Tool 12″ DRILL BIT For removal of carburetor plug. (mixture screw plug) 1/8″ bit x 12 inch length. 35-1186 YM-33217-16 JET DRIVER 35-2270 Perfect for removal of jets from small recessed passages
Filed Under (Honda) by admin on 29-01-2011
INSPECTION/ADJUSTMENT PROCEDURE 1. Remove the right engine side cover (see S/M Page 2-4). 2. Check the cable clearance on the N (neutral) and R (reverse) cables. Note: It is not necessary to remove the center inner fairing or inspect the reverse shift actuator. . 6. Push the reverse shift switch to “OFF” and turn off the ignition. 7. Tighten the reverse cable lock nuts. 8. Reinstall the right engine side cover. PARTS INFORMATION No parts are required for this procedure. WARRANTY INFORMATION Normal warranty. After completion of the inspection/adjustment, submit one claim per VIN using the following information only: Template #: GL#5 Flat Rate Time = 0.3 hours The reverse cable lock nuts may not have been properly tightened on some GL1800 units. We have developed a procedure to inspect and adjust any affected units. Please follow the INSPECTION/ ADJUSTMENT procedures included in this Service Bulletin. AFFECTED UNITS 2002 GL1800 units with VIN range: 1HFSC470*2A102303 through 1HFSC470*2A102622 * indicates check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection.
Filed Under (Yamaha) by admin on 19-01-2012
When I first started working on bike many years ago, I learned the danger of stripping the heads of Philips screws when removing or installing them on motorcycles. I remember the two worst screws were the casing side-cover aluminum screws and carburetor bowl screws. I think I tried every method of screw removal after they were stripped. Vice grips, better tipped screwdriver, hammer, drill, and other tools were used. One way I learned to remove stripped screws is to re-make the Philips head into a flathead screw. Cutting a slot in the top of the screw and then use a flat-head screwdriver to remove the screw. On some parts this technique can work, other parts and screws it may not. The Philips screws on the bottom of the V-Star carburetor bowls are VERY prone to stripping. In fact, I will not start a carburetor cleaning without new hex head screws to replace the original Philips bowl screws. Replace the bowl screws for yourself if you keep the bike, or for the next rider that will appreciate the hex-head screws when they clean the carburetors. Not many other parts on a V-Star have screws that are prone to stripping. This documentation is to help riders with motorcycle maintenance. Some riders will find themselves with the problem of removing stripped screws. A carburetor cleaning can quickly double in time when you realize the hardest part of the job is removing bowl screws after they strip. And then realizing you do not have the replacement hex-head screws available and must now go to the hardware store.