sitting the carburetors on a cbr 900rr stage 3 jet kit

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Triumph SU CARBURETORS SERVICING AND TUNING

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Filed Under (Triumph) by admin on 29-10-2010

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Jets: These are made in various sizes ranging from.099 inches to.1875 inches, the larger sizes being used only for racing or very high performance engines. The two sizes most commonly found on production cars are the.090 inch and the.100 inch. The size of the jet will be found stamped on the jet head. The figure “nine”wilt indicate that it is the.090 inch and the figure “one”will indicate the.100 inch jet. When tuninga production car the jets size should be checked to make sure that it is of the size recommended by the manufacturers. Centering of Jet: If for any reason, the jet assembly has been removed, it will be ne cessary to recenter the jet. First, remove the clevis pin at the base of the jet which attaches the jet head to the jet operating lever. Withdraw the jet completely and remove the adjusting nut and spring, then replace the adjusting nut, without its spring, and screw it up toits highest position. Slide the Set into position until the jet head is against the base of the adjusting nut. When this has been done, find out if the piston is perfectly free by lifting it up with the finger and allowing it to drop. If the piston is not entirely free, slacken the jet screw and manipulate the lower part of the assembly, including the projecting part of the bottom half of the jet bearing, adjusting nut, and jet head. Make sure that this assembly is now slightly loose. The piston should then rise and fall quite freely as the needle is now able to move the jet into the required central position. The jet screw should now be tightened and a further check made to determine that the piston is still quite free. When complete freedom of the piston is achieved the jet adjusting nut should be removed, together with the jet, and the spring replaced. Experience has shown that a large percentage of carburetors, which have given trouble has been due to the incorrect centering of jets. Jet Needles— These are made in a great variety of sizes, probably now well over two hundred and fifty, and each type of engine hasaneedlethat has been selected, after very careful tests have been carried out, to give the best all-round performance. Most manufacturers actually give three alternative needles for each type and size of engine, these needles clearly being listed by the manufacturer “Standard”, “Rich”or”Weak”and before tuning is started the needle, which is marked on the shank should be checked against the manufacturer’srecommendation to make quite sure that the right needle is fitted; this is most important.

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Yamaha V-Star 1100 Needle/ Jet Kit REMOVAL AND INSTALLATION MANUALS

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Filed Under (Honda) by admin on 27-12-2011

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To install this needle and jet kit: • Remove carburetors from the engine per Yamaha shop manual procedures. Note: Always perform internal carburetor work in a clean area. • Remove the vacuum slide from each carburetor. • Remove the OEM needle, spacer and washers, noting order of assembly. (Note; the washers are used as shims to raise the needle, each is equivalent to ½ clip position, use these to fine tune the needle) • Counting from the top to the bottom, install the new Baron needle clip on groove #4 of the replacement Baron adjustable needles. The top is the blunt end of the needle. • Reinstall the OEM spacer and washers as shown in the figure below. • Reinstall the vacuum slides along with the diaphragm spring and reattach the diaphragm covers Note: Verify that the slides maintain their full range of movement! • Drain the fuel from the float bowls and remove the bowl covers. • Remove the OEM main jets and replace them with Baron’s supplied Mikuni main jets. Install the “base setting” main jets as indicated above. NOTE: V-Star 1100 carburetion runs staggered jetting! Make sure the front cylinder’s carburetor gets the larger main jet (numerically), and the rear cylinder’s carburetor gets the smaller main jet . Important! Extra jets have been included in your kit. These will help you fine-tune the carburetors for changing conditions. These conditions include climate and weather patterns in your area as well as exhaust equipment on your motorcycle. Barons determines the jet and clip recommendations that best suit your average riding conditions based upon information supplied to us at the time of your order. Changes in weather, altitude or modifications to your exhaust system may require jets other than those supplied. • Thoroughly clean the inside of the float bowls prior to reinstalling them. 311 #1 Industrial Way – Fallbrook, CA 92028 – USA Phone: (760) 731-1200 Fax: (760) 731-1284 E-mail: tech@baronscustom.com Website: www.baronscustom.com Included in this kit: (4)Mikuni main jets #107.5, 110, 112.5, 115, (2) titanium needles, (2) clips, (8) cap-head allen screws Tools required: 3-4-5 mm allen wrenches, 10&12 mm sockets, 10mm end wrench, phillips & flat screwdrivers, pliers, drill. Revision 4.0 • Reassemble the carburetors by reversing the order of above steps. Use the new supplied cap head Allen screws in place of the OEM Phillips head screws for the float bowls. • Locate the fuel mixture screws – they will either be a screw head or a brass plug. If it is a screw head, skip to step c . If you see a brass plug with a small hole in the center, proceed as follows: a. With a 5/32″ drill bit, carefully and slowly drill through the fuel mixture plugs

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Honda Motorcycle Na vigation Kit

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Filed Under (Honda) by admin on 28-11-2010

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Honda Motorcycle Na vigation Kit Honda Motorcycle Navigation Kit G e n e r i c A c c e s s o r i e s 2 0 0 8 For your peace of mind Honda Genuine Accessories are carefully designed, researched and stringently test ed tot he highest standards. And since they’re all Honda approved you’llknowthat they’rejustastoughand well made as your Honda motorcycle. Please Note -All prices quoted are correct at time of printing and are subject to change without prior notice. y e a r w a r r a n t y GENUINE ACCESSORIES Honda Motorcycle Navigation Kit Model Part Number Description RRP Remarks NAKED CBF 600 08A 40MER800B CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY CBF 600 08A 40MER800A CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, £549.99 EARPHONE, MANUAL, MCC AR KIT, UN I TAT TACHM ENT KIT, BATTERY ON/OFF XL700V 08A 40MFF800 * CONTAINS NA VI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EARPH ONE, MANUAL, 08A 30MFF800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY XL 1000V 08A 40MBT800 CONTAINSNAVI GAT ION UNIT COMPONENT, £549.99 Must be combined with quartet harness CONTROLLER, EAR PH ONE, MANUAL, 08A 30MBT800 MCCAR KIT, UNI TAT TACH ME NT KIT, BATTERY TOURERS/SPORT TOUR ERS DN-01 08A 40MEH800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, AND BATTERY -CONTAINS 08A 30MEW800 ADDITIONALSTE ERIN G HANDLE C LAMPS FORV ISU AL INTE GRAT ION OF THE COMPONENT NT700V 08A 40MEW800 CONTAINSNAVI GAT ION UNIT COMPONENT, CONTROLLER, EARPHONE, £549.99 Must be combined with quartet harness MANUAL, MC CAR KIT, UNI TAT TACH MEN T KIT, BATTERY

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HARLEY DAVIDSON SKULL FOOT BOARD INSERT KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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Kit 50704-04 is an Operator Footboard Insert Kit. •This kit fits all 2004 and later FLHRS/I (Road King® Custom) model motorcycles. •This kitalso fits 1986 and later FLHR/I/CI, FLHT/C/CI/CUI and FLTR/I models equipped with Swept-Wing footboard pans 50683-04 (right) and 50688-04 (left) . Kit 50704-04 contains the following items: QTY DESCRIPTION PART NO. 1Operator footboard insert (right) 50705-04 1Operator footboard insert (left) 50706-04 Kit 50707-04 is a Passenger Footboard Insert Kit. •This kitfits 2004 FLHTCSE models, and all 1986 and later Touring model motorcycles equipped with Swept- Wing Grooved Passenger Footboard Kit 50357-04 . Kit 50707-04 contains the following items: QTY DESCRIPTION PART NO. 1 Passenger footboard insert (right) 50708-04 1 Passenger footboard insert (left) 50709-04 Kit 50710-04 is an Operator Footboard Insert Kit. •This kitfits all 1980 and later Touring models except FLHRS, and 1986 and later FL Softail®model motorcy- cles equipped with footboard pans 50621-79A. Kit 50710-04 contains the following items: QTY DESCRIPTION PART NO. 1Operator footboard insert (right) 50711-04 1Operator footboard insert (left) 50712-04 Kit 50713-04 is a Passenger Footboard Insert Kit. •This kit fits all 1986 and later Touring models . •This kit also fits 1986 and later FL Softail models when equipped with accessory passenger footboard kits (Part Number 50602-89B, 50955-97A, 50955-00 or 50602-00). • This kit iscompatible with Chrome Passenger Footboard Cover Kits (Part Numbers 50782-91, 50193-96, 50194-96 and 50246-00). • This kit is notcompatible with Leather Passenger Footboard Fringe Kits (Part Numbers 50947-98 or 50956-98). Kit 50713-04 contains the following items: QTY DESCRIPTION PART NO. 1 Passenger footboard insert (right) 50714-04 1 Passenger footboard insert (left) 50715-04 Installation, Kit 50704-04 (For Swept-Wing Operator Footboards): Removing Previously Installed Inserts 1. Apply liquid dishwashing soap to the rubber beads protruding through the bottom of the footboard pan. 2. With the operator footboard in the “up” position, use a screwdriver to work the rubber footboard beads out through the top of the footboard. 3. Repeat the above steps for the remaining footboard insert. Installing the New Inserts 4. Apply liquid dishwashing soap to the rubber beads on the new footboard insert. 5. Place the footboard insert into position on the footboard pan. From the underside of the footboard, use a pliers to pull each rubber bead into its mating hole in the footboard pan until the beads protrude through the pan. 6. Repeat the above steps for the remaining footboard insert.

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HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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Yamaha Road Star NEEDLE/ JET KIT INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 10-11-2010

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1. Remove the vacuum slide from the carburetor. 2. Remove the OEM needle, spacer and washers, noting order of assembly. 3. Counting from the top to the bottom, install the new Baron needle clip on groove #4 for 04-07 models and on groove #5 for 99-03 models of the replacement. NOTE: Baron adjustable needle – The top is the blunt end of the needle. 4. Reinstall the OEM spacer and washers as shown in this diagram. 5. Reinstall the vacuum slide along with the diaphragm spring. 6. Reattach the diaphragm cover back and tighten screws. NOTE: Verify that the slide maintains its full range of movement. 7. Drain the fuel from the float bowl and remove the bowl cover. 8. Remove the OEM main jet and replace it with a Barons genuine Mikuni main jet. Install the correct main jet as indicated in JET SELECTION area above on this page. Our install guides provide a basic outline on the proper installation of our products. Further tuning and/or fitment may be required. Page: 2 BA-2420RD NEEDLE/JET KIT – Yamaha Road Star (99-07) 9. Thoroughly clean the inside of the float bowl prior to reinstalling it. 10. Reassemble the carburetor by reversing the order of step #1 through step #10. Use the new cap head allen screws in place of the OEM phillips head screws. 11. Locate the fuel mixture screw – it will either be a screw head or a brass plug. If it is a screw head, skip to step #11c. 11c. If you see a brass plug with a small hole in the center, proceed as follows: With the drill bit, carefully and slowly drill through the fuel mixture plug. CAUTION: The fuel mixture screw is located directly beneath this plug. Be prepared to stop the drill and remove the bit the instant you break through the plug. Insert the self-tapping sheet metal screw into the drilled hole and remove the plug. With air/fuel screw now accessible, use a flat blade screwdriver to turn the screw clockwise until it seats, then carefully turn it counter-clockwise 3 1/2 turns. Refer to step #16 for assistance in fine tuning the setting of the air/fuel adjustment screw. 12. Reinstall the carburetor. We strongly suggest that you attach the throttle cables prior to mounting to intake manifold. 13. Reconnect the fuel line, ensuring the clamp is firmly in place. 14. Reinstall all vent hoses and electrical connectors that were previously removed, checking for any obstructions or blockage. 15. Reinstall the OEM air filter assembly or, if you are installing our Big Air Kit (BAK), follow the instructions that accompany that kit, then continue with next step. NOTES: When the BAK is installed, the vent hose that terminated on the rear of the OEM airbox can be relocated in any safe position that does not kink or pinch it. It is important to verify proper throttle operation before starting the engine.

Daytona 675 Motorcycle Race Kit Installation Manual

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Filed Under (Triumph) by admin on 29-10-2010

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Remove the existing cylinder head gasket in line with the procedures detailed in the Daytona 675 service manual. 2. Fit the chosen race kit cylinder head gasket following the procedures detailed in the Daytona 675 service manual. Caution The use of the following race kit cylinder head gaskets will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. Item Description Qty 1 Head gasket (t = 0.65mm) 1 1 Head gasket (t = 0.60mm) 1 1 * Page 7 of 29 © Triumph Designs Ltd 2007. Cams, Valve Spring & Sprocket Kits Parts Supplied Camshaft Inlet Kit – A9618055 Camshaft Exhaust Kit – A9618056 Valve Spring Kit – A9618058 Camshaft Sprocket Kit – A9618057 Warning The race kit must be fitted as a complete set. If it is not fitted as a complete set a failure may result which could cause loss of motorcycle control and an accident. Caution The use of the Camshaft, Valve spring & Sprocket race kits detailed below will require changes to the fuelling settings. To alter fuelling settings a third party programmable control unit will be required. 5 5 4 1 3 2 4 3 Item Description Qty 1 Cam assy, inlet, race 1 Item Description Qty 2 Cam assy, exhaust, race 1 Item Description Qty 3 Valve spring, 14.4id, race12 Item Description Qty 4 Sprocket, camshaft, 34T 2 5 Socket head cap screw, Encapsulated, M6x10 4
Page 8 of 29 © Triumph Designs Ltd 2007. NOTE •The standard inlet cam is 9.25mm max lift and 258.50o duration. The race kit inlet cam is 9.25mm max lift and 268.74o duration. •The standard exhaust cam is 8.5mm max lift and 246o duration. The race kit exhaust cam is 8.5mm max lift and 262.21o duration. •The race kit valve spring must be used in conjunction with the standard spring platforms and retainers. The fitted length of the race springs is the same as the standard spring. 1. The race kit valve springs should be assembled in the same manner as the standard valve springs. Follow the procedure detailed in section 3 of the Daytona 675 service manual. Ensure the springs are installed with the close wound, colour coded end of the springs facing downwards, towards the piston. 2. The race kit camshafts should be assembled in the same manner as the standard camshafts. Follow the procedure detailed in section 3 of the Daytona 675 service manual. 3. The race kit cam sprockets should be mounted and secured to the camshafts using the slotted holes in the sprocket. The slotted holes allow adjustment of the valve timing. The circular holes in the sprockets are for Triumph service tool T3880102 and should not be used to mount the sprockets to the camshafts. NOTE •No timing marks are included on the race sprockets. Race engines will typically have different depths skimmed off the cylinder head and, therefore require specific individual timing. 4. The camshafts should be timed using cam degreeing equipment which typically consists of a degree wheel, pointer, dial indicator and piston stop. Optimum cam timing will depend on the exact specification of the engine, but a recommended starting point is 104o IMOP (Inlet Maximum Opening Point) and 104o EMOP (Exhaust Maximum Opening Point). 5. Always check the inlet and exhaust piston to valve clearance for the timing selected to use, before running the engine. You must ensure both clearances are adequate. As a guide, the standard nominal piston to valve clearance is 1.3mm inlet & 1.5mm exhaust

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HARLEY DAVIDSON HEEL REST KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 10-04-2011

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Models Kit 50227-01 is designed for forward controls and fits: •1989 and later FX Softail Models with Original Equipment (OE) Forward Controls, •1993 through 2002 FXDWG, •Dyna models equipped with Forward Control Kit 49080- 93 or 49080-93A. Kit 50227-01 does not fit Dyna models equipped with Forward Control Kit 49080-03 or Forward Control Footrest Support 33695-03 (left) or 33697-03 (right). Kit 50236-01 is designed for mid controls and fits: •all 1990 and later Dyna Model Motorcycles with Original Equipment (OE) Mid Controls. Additional Parts Required Proper installation of this kit also requires installing a pair of Heel Rest Pegs, or Shifter Pegs, which can also be mounted as heel rests. Refer to the appropriate Parts Catalog for stock shifter pegs, sold separately. The current Harley-Davidson Genuine Motor Accessories and Parts catalog also has a selection of Heel Rest Pegs or Shifter Pegs and matching Footpegs. Any shifter peg style that is symmetrical in design can be used as a left or right side heel rest. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer. Kit Contents See Figure 1 and Table 1. INSTALLATION NOTE See Figure 1 for the following procedure. 1. Remove the screw (B), lock nut (C) and spring washer (E) securing the left footpeg to the footrest support bracket (A). Save the hardware for later installation. NOTE Heel rest levers are side-specific. Levers mount so the set screws are on the underside. 2. Obtain a Heel Rest Peg or Shifter Peg (D) (purchased separately) and the left side heel rest lever (3). Apply Loctite® 243 (7) to the threads of the peg and install it to the left heel rest lever. 3. Obtain the screw (B), spring washer (E) and lock nut (C) removed in step 1, and the heel rest lever and peg assembly (D). Position the lever assembly to the desired angle on the mount, and slide the lever assembly with the spring washer into the footrest support bracket as shown. NOTE Splines on the lever and mount provide for a limited range of heel rest angle adjustment. For Kit 50227-01. The heel rest lever (3) can be adjusted after the mount (1) is attached but before the set screw (2) is installed. Slide the lever inward off the spline, and rotate it to the desired angle. For Kit 50236-01. The heel rest lever (3) angle cannot be adjusted after the mount (1) is attached without removing them from the footrest support bracket (A). Check to ensure the heel rest (D) is in a comfortable position before tightening the mounting hardware. 4. Install the original screw (B) and lock nut (C) to secure the heel rest assembly to the footpeg mount. Tighten to 33 ft- lbs (45.6 Nm). 5. Obtain a screw (6), spring washer (5) and nut (4) from the kit. Install the footpeg to the heel rest assembly and tighten to 33 ft-lbs (45.6 Nm). 6. Obtain a set screw (2) from the kit. Apply Loctite® 243 (7) to the threads, and install the set screw to the heel rest lever. Tighten to 16 in-lbs (1.8 Nm). 7. Perform Steps 1 through 6 for the right side. USE

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HARLEY DAVIDSON EFI SCREAMIN' EAGLE BIG BORE EFI STAGE 2 KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 29-01-2011

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INSTALLATION Installation of this kit is divided into six steps: 1. Big-Bore Cylinder and Piston Conversion 2. High Performance Camshafts 3. High Performance Clutch Diaphragm Spring 4. High Performance Air Cleaner 5. Calibrate the ECM 6. Exhaust NOTES This Big-Bore Stage 2 kit is intended for High Performance applications only. This engine-related performance part is legal for sale or use in California on pollution-controlled motor vehicles. Engine-related performance parts are intended for the experienced rider only. -J04173 1 of 5 The air cleaner contained in these kits is designed to perform with these kits only. Any other combination of components is not confirmed to be legal for street use. The Product Information Label contained in this kit is required in the state of California only. This label is required to aid in passing the California Smog Check Program. Place the Product Information Label on the right side of the frame, directly beneath the VIN sticker. Do not place the label on motorcycles other than those specified in the Instruction Sheet. Gaskets provided in the 1690 conversion kit eliminate the need for original head gasket O-rings. For this reason, DO NOT install the Original Equipment (OE) O-rings (Part Number 11273) to the top of cylinder dowels, or severe engine damage may occur. Big-Bore Cylinder and Piston Conversion NOTE Installation of this kit requires removal of the cylinder heads, cylinders and pistons. Refer to Section 3, ENGINE: STRIPPING MOTORCYCLE FOR SERVICE and TOP END OVERHAUL of the applicable Service Manual for instructions. High Performance Camshafts NOTE Installation of this kit requires removal and re-installation of the cam support plate. Refer to Section 3, ENGINE: BOTTOM END Cam Support Plate, Removal and Disassembly/Assembly (Camshaft, Camshaft Bearings) of the applicable Service Manual for instructions. Measuring Piston-to-Valve Clearance After installing non-stock cams, check piston-to-valve clear- ance. 1. Apply 1/8-inch (3 mm) layer of clay to crowns of pistons in areas where valves meet pistons. 2. Refer to the appropriate Service Manual and assemble the heads and valve train, and tighten cylinder studs to torque specified. 3. Turn engine through two complete revolutions by hand. 4. Remove heads and measure clay at its thinnest point. NOTE Clay must measure 0.080 inch (2.03 mm) at its thinnest point. If this measurement does not meet minimum thickness, depth of valve notches must be increased. The depth of the notches must not exceed 0.135 inch (3.43 mm). Measuring Valve-to-Valve Clearance NOTE Wait ten minutes before turning the engine after installing push rods. This allows tappets to bleed down and prevents you from bending push rods or valves. 1. Rotate the engine so that both valves of the front cylinder are partially open. Shine a light through the exhaust port and look through the spark plug hole to view the valves. Turn engine, if required, to the point where the exhaust evel sensor to the fuel pump with screw (3). Tighten the screw enough to seat the fuel sensor against the mounting tab e. Route fuel level sensor wiring under the fuel hose and connect the fuel level sensor to the low fuel switch connector on the fuel pump module. If necessary use the jumper harness (Figure 4, item 5). f. See Figure 2. Secure the fuel pump wires and con- nectors

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KTM 250/ 300/ 380 SX,MXC,EXC ENGINE REPAIR MANUAL

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Filed Under (KTM) by admin on 12-11-2010

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Repair manual KTM 250 / 300 / 380 Art No 3206004 -E 2-2C main jet jet needle jet needle air control screw idle adjusting screw idle jet throttle valve Idling range A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2 . Only make adjustments when the engine is hot. To this end, slightly increase the idling speed of the engine by means of the idle adjusting screw. Turning it clockwise produces a higher idling speed and turning the screw counterclockwise produces a lower idling speed. Create a round and stable engine speed using the air control screw (basic position of the air control screw = open by 1.5 turns). Then adjust to the normal idling speed by means of the idle adjusting screw. 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. Full throttle range D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating or if the engine rings, after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. mixture too rich: too much fuel in proportion to air mixture too lean: not enough fuel in proportion to air 1 2 OPERATING RANGES OF THE CARBURETOR 2-3C Carburetor adjustment Basic information on 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 MOZ). Mixing ratio 2-stroke motor oil : super fuel 1:40 – 1:60. Basic information on a change of 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:

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