how to adjust pz20 carb

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KAWASAKI 1500 CARB THUNDER Air Filter Kit Installation And removal Instruction

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Filed Under (Kawasaki) by admin on 25-10-2010

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1) Remove Seat 10mm KAW 1500 CARB ADPTOR QTY PARTS LIST 1 1500 CARB ADAPTOR 1 3″ PIECE OF HOSE 1 DOUBLE BARB 1 L-BARB 1 3/8″ RED PLUG 1 ¼” BLACK VACCUM PLUG 1 M6-1 NYLON INSERT LOCK NUT 3 M6-1 X 16 FLAT SOCKET HD CAP SCREW 1 170 MJ 1 INSTRUCTIONS 2) Remove Dash Plaque 8mm bottom Bolt only 3) Lift from bottom then Remove speedo cable 4) Disconnect Electric Plugs 5) Remove 12mm bolts holding tank 6) Turn petcock OFF – Pinch off fuel line. 7) Disconnect the electric Plug under speedo opening 8) Lift Tank at Rear – Disconnect two Vent Lines; Fuel gage Vent will Pull up – Remove. 9) Remove Chrome Air Cover. 10) Left side Remove two screws – 10mm bolt in side Air box. Pull hoses off Remove 1″ hose going to cross over Tube. 11) Remove two 8mm bolts on Bracket – Remove Bracket 12) Remove Screw on Top of air Box Snorkel 13) Remove both side covers 14) Remove air Backing plate right side (Crank Case Breather hose that connects to stock air box will connect to new) 15) Remove Bracket that holds Carb and holds Backing Plate 16) Take idle adjustable Knob loose – let hang loose 17) Take Choke Knob out of holding Bracket 18) Hose that went to cross over tube MAY BE PLUGGED OR VENTED your Choice (Fresh air unit) ** 98′S or any models with carb warmer should disconnect carb warmer by pinching off line on each side of connector that plugs into carb on bottom. Small bracket with one screw directly on the bottom of carb. 19) Loosen Clamp that holds Carb to intake Manifold, Carb will hang loose 20) Remove intake Manifold 5mm Allen- Remove crossover tube. 21) (- BE CAREFULL-) LINE IT UP RIGHT- Replace intake Manifold (YOU MAY TO SEAL THIS WITH A SEALER LIKE PERMATEX) ( BE SUPER CAREFUL TO KEEP INTAKE COVERED DURING EACH STEP. SCREWS CAN FALL ONTO INTAKE) 22) Drain Float Bowl 3mm allen – very bottom of carb 23) Remove Float Bowl 4 screws (#2 Phillips) let hang down 24) Remove main jet, if Emulsion tube comes out use 8mm and Flat tip to separate jet from Emulsion tube. 25) Install with new jet 26) CAREFULLY Reinstall Float Bowl Cover 27) If installing Needle Remove Top Cover of Carb, Carefully pull the slide out. ( BE CAREFUL WITH DIAPHRAM) Remove Spring + Needle Install new Needle (WE RECOMMEND THE 3RD CLIP FROM TOP WITH TWO WASHERS ON TOP. REINSTALL 28) Be sure to reseat diaphragm – BE CAREFUL Reinstall Cover. 29) Install Carb to Intake – reconnect carb warmer if applicable 30) Reattach idle adjustment 31) Reattach Choke 32) Reattach Bracket in front of Carb- 33) Take Center bolt mount Rubber Gromlet from Stock Air box Plate install in to new Air box Adapter use stock Bolt, Attach to Bracke

HW Prowler Carburetor Installation Instructions

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Filed Under (Mikuni) by admin on 31-10-2010

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1. Remove both seats and the plastic seat pans under the seats. 2. Remove the engine cover 3. Remove the air-box by removing the cross-bar support that runs under the air-box to the framing on each side by the seat framing and disconnect the air box from the carburetor and from the plastic intake in the rear. 4. Disconnect the engine breather hose from the bottom of the air box 5. Set the air-box to the side 6. Disconnect the plug going to the stock carburetor, this is the electronic choke. Wrap the end left on the vehicle with electrical tape. 7. Cut the fuel line just above the fitting on the passenger side of the carb 8. Remove the side cover off the drivers side of the carb where the throttle cable goes in, see fig. #1 9. Pull the throttle cable out and then remove the throttle cable end from the throttle plate See Fig. #2 10. Loosen the clamp on the rear of the carb holding the carb on 11. Pull the carb out of the intake boot 12. Set OE carb to the side. 13. Push the new Carb into the intake boot making sure the carb is perfectly vertical and then tighten the clamp back up. The new carb is slightly larger than the stock one so some additional pressure will be needed to get it in. 14. Route all the breather lines connected to the carb down under the carb. 15. Connect the throttle cable onto the new carb but putting the cable end in the bottom hole of the throttle plate on the passenger side of the carb allowing the cable to ride in the slot in the plate and then turn the throttle plate clock wise allowing the threaded end of the cable to fit into the lower round hole of the throttle cable connection plate. See Fig. #3 16. Make sure you have a nut on each side of the plate turn the nut on the outside of the plate to take up the slack in the throttle cable then tighten the nut on the inside of the plate. See Fig. #3 17. Push the fuel line onto the fuel inlet on the passenger side of the carb and install the supplied clamp to hold it on. The fuel line will be a little hard to push on. 18. DO NOT ATTEMPT TO INSTALL THE CHOKE CABLE PARTS SUPPLIED IN THE KIT UNTIL AFTER THE CHOKE CABLE ITSELF IS INSTALLED AND READY TO SCREW INTO THE CARBUETOR. 19. To install the supplied choke cable, drill a 3/8″ hole in the dash on the left side of the steering wheel in a location convenient to your left hand. 20. Remove the plastic nut from the bottom of the choke handle on the choke cable. 21. Push the choke cable thru the hole you drilled and then slide the nut over the cable to the inside of the dash and reinstall back on the back of the choke mechanism. Some dash screws maybe needed to be removed to accomplish this

Adjusting the Pekar K68 for Dnepr or Ural

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Filed Under (Tips and Review) by admin on 11-11-2010

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1. Make sure the ignition timing is correct 2. Adjust the valves as necessary to ensure proper operation 3. Run the engine to warm it up a bit 4. Adjust the float setting. To do this, remove the carburetors (leave the throttle cables attached), remove the bowl and turn the carburetor upside down (fuel will spill). The float should look like this: Adjust as necessary by bending the float support (#37 in Figure 1). Reinstall Installation and idle adjustment 1. First you must adjust the idle. It is acceptable per the manual to adjust the idle by using the idle adjust screws (11). This usually involves screwing them then backing out 1 to 1.5 turns. Or you can adjust looking at the sliders 2. If installing the carburetors: a. Remove the cover (2) b. Reomve the slider (3) c. Place the throttle cable through the guide (18) with the spring (4) on the cable. d. Route the cable through the slide catch (6) e. Insert the slide assembly into the chamber and make sure it easily slides up and down. Direct the needle (8) into the opening of the diffuser (angled side visible). f. Screw assembly together and verify via throttle movement that slide moves freely. Attach fuel delivery lines to (12). 3. Using the idle set screw (11) raise the slider so the lower edge is 1-2 mm. 4. Assemble to engine using the proper gaskets (paper – felt – paper). 5. Using the locknut (26) adjust the free play of the throttle cable (2-3 mm) 6. Adjust the idle mixture screw – turn in completely then out 1 to 1.5 turns. * Starting using the K68′s (cold weather) 1. Verify fuel flow. Apply choke (pull 52 in Fig1). 2. Using the ticklers (13) allow fuel to enter the bowl until fuel drains from (14) 3. With the ignition off, kick 1 or 2 times 4. Turn ignition on, and as soon as engine is warmed up (maybe sooner) push choke mechanisms to open choke Idle Adjustment (engine running and warm) 1. Remove one of the spark plug caps, and with the cap shorted, adjust (11) to decrease RPM’s to a point of being minimally steady. 2. Adjust the mixture (15) out until RPM’s decrease. Turn in until RPM’s increase slightly. Then turn in screws ¼ to 1/3 revoultion. 3. Do the same for the second carburetor with the first spark plug cap shorted. 4. With both cylinders, adjust each idle (11) on each carburetor the same amount each until it’s at a steady, minimal RPM. Use small changes. (at this point you can use your airflow tool to check). 5. Sharply increase, then decrease throttle. Then engine must return to low RPMs smoothly. If the engine goes below limits, readjust (11) from step 4. Synchronization of the K68 Note: Rather than using the opposite cylinder shorted to test the pull of the live cylinder carburetor, you can use something like a Twinmax connected to the test ports (27 Fig 1). Or, if you have a model without these ports, use a Synchrometer (Appendix 2) held against the face of the carburetor. These tools merely show airflow passing through each carburetor (which is dependent on the position and wear on the slide). If using these tools, it’s not necessary to do the following steps. You wil want to use a throttle guide (Appendix 1), to show airflow at various throttle settings. Using the flow meter of your choice make sure each carburetor is the same at the various throttle settings. 1. Place the motorcycle on the center stand ensuring the rear wheel is suspended 2. Make sure you have large area to work with (safety issues here) 3. Shift into the highest gear with the engine running 4. Short one spark plug cap to the cylinder (using a nail or something in the fins) 5. Increase the speed to 40-50 km/hr 6. Fix the throttle using the throttle (maybe using a throttle stop screw under the throttle housing). 7. Reconnect other cylinder and using the opposite carburetor determine the speed which should be the same as the first. 8. Adjust the position of this slide to achieve the referenced speed using the locknut at the top of the carburetor.

KAWASAKI TERYX EFI Installation Instructions.

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Filed Under (Kawasaki) by admin on 08-02-2011

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Basic Tuning Adjustments 1. The following instructions are for basic fuel tuning. Modes 1,2, & 3 are allowing adjustments to increase and decrease the amount of fuel the engine needs. Modes 4 & 5 are for advanced tuning only. DO NOT change modes 4 & 5 when doing basic tuning! 2. To help understand how these modes work, you can think of them as if you were working with a carburetor. 3. Remember each time you push the MODE button you will be advancing to the next mode. Push the MODE button once and you are now in mode 1, push the MODE button again and you are now in mode 2 and so on. You only need to be concerned with modes 1, 2 & 3 for basic tuning. Modes 4 & 5 are for advanced tuning ONLY. 4. If you need to go back to the settings that were pre programmed when you purchased the controller, just look at the picture in each mode, the colored square represents where the settings were when you purchased the controller. 5. Looking at the controller you will see eight lights with numbers under them, this is what you need to look at when changing settings. The #1 light on the controller represents the leanest setting. TRINITY RACING DOES NOT TAKE REPONSIBLITY FOR DAMAGES THAT MAY OCCUR DURING OPERATION OF YOUR VEHICLE UNDER IMPROPER JET SETTINGS. IT IS THE FINAL RESPONSIBLITY OF THE OWNER/RIDER TO ADJUST JETTING TO SPECIFIC RIDING CONDITIONS AND ELEVATION BEFORE RIDING. WARNING! 1.877.FAS TOYS 2.Remove both seats 6. Re-install engine cover and seats. 6. Mode 1 green light represents idle & cruise adjustment (i.e. pilot jet). To adjust this setting push the MODE button once and then push the plus or minus buttons to adjust fuel as needed. 7. Mode 2 yellow light represents an additional amount of fuel added during acceleration (i.e. needle position). To adjust this setting, push MODE twice and then push the plus or minus buttons to adjust fuel as needed. 12 34 56 7 8 12 34 56 7 8 8. Mode 3 red light represents more fuel being added during full throttle (i.e. main jet). To adjust this setting push the MODE button three times and then push the plus or minus buttons to adjust fuel as needed. 9. If you are confident about your tuning skills and feel you need to adjust other parameters, see Advanced Tuning. 12 34 56 7 8 Advanced Tuning Adjustments 1. Advance tuning has two modes in which to adjust. They are called mode 4 and mode 5. In basic tuning, you are changing the amount of fuel that the engine receives, but with advance tuning, you will be changing when the fuel will be available. In each mode you can adjust how soon the fuel delivery occurs. 2. Mode 4 yellow light and blue light represent when the fuel delivery is available during partial throttle acceleration. To adjust this setting, push the MODE button four times and then push the plus or minus buttons to adjust fuel as needed. Only the yellow light will be changing.

42MM MIKUNI FLATSLIDE CARBURETOR INSTRUCTIONS

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Filed Under (Mikuni) by admin on 31-10-2010

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To install, remove the stock carb per Yamaha shop manual procedures. Remove stock throttle cables. Install Mikuni HSR carb into intake manifold and tighten manifold clamp. Install new HSR series throttle cables and adjust cable slack per Yamaha shop manual procedures. Hook fuel line to HSR carb and fasten clamp.* Start motorcycle and fine tune HSR carb for proper running per supplied Mikuni tuning manual. *NOTE: Mikuni HSR series carburetors are designed for gravity-feed fuel systems. You should bypass your stock fuel pump and directly feed your HSR carb right from the fuel petcock. We have noted, though, that you may not be able to get good fuel flow from your Road Star fuel tank in low-fuel situations. You may run your stock fuel pump with the HSR carb, but to do so requires the purchase and installation of an adjustable fuel pressure regulator (set at 1/2 to 1 lb. of pressure). These are available from most auto parts stores. The stock carb has 2 wires running to the lower rear of the float bowl , these were for a carb warmer, they are not used in this application. Unplug these wires at the main wire harness and retain with your stock carb. The Road Star ignition system uses data from the stock throttle position sensor (TPS) to manage your ignition timing. It is necessary to give the bike this information. You may do so by removing the TPS sensor from the stock carb, leaving it plugged into the main wire harness (the sensor must be fixed to a closed-throttle position), or you may locate the plug for the TPS on the main wire harness and test the leads – you will find one ground, one with .5V and one with 1.5V. Connect the 1.5V to the ground and this will give the bike the same information as stock fully closed throttle. The output of the OEM fuel pump is too high and will cause fuel overflow in the HSR carb, resulting in a possible dangerous fire hazard

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