I got the carb installed last night and took pics along the way. My bike started on the first pull with the choke but was running rich in the low to mid area and wouldn't rev. I have yet to work on the jetting.
Start by removing your plastics if you wish but it's not necessary.
1. Remove the fuel line from the stock carb
2. Remove the air filter from the stock carb
3. Loosen pinch bolt and position carb so you can access the screws on the top of the carb, remove the screws and remove the slide and choke lock. Set the carb body aside.
1. Below is a pic of the air filter I used. It was locally available and was only $9. It has a 39mm opening, you need a filter with a 32mm opening(K&N #s RU-0060,RU-0070, UNI UP4125 single stage,UP4125ST dual stage). I made due by making a rubber bushing/adaptor instead of waiting for special order.
2. Install the filter on the carb and remove the throttle cable adjuster and boot from the BadAzz Carb.
3. Screw the 45degree elbow into the carb and install a sealing washer and bushing. My carb didn't have a bushing in it when I received it so I had to make one out of a piece of 3/4" PVC pipe. The sealing ring and vent elbow came from a Pacco carb I had lying around.
1. Below is a pic of the air filter I used. It was locally available and was only $9. It has a 39mm opening, you need a filter with a 32mm opening(K&N #s RU-0060,RU-0070, UNI UP4125 single stage,UP4125ST dual stage). I made due by making a rubber bushing/adaptor instead of waiting for special order.
2. Install the filter on the carb and remove the throttle cable adjuster and boot from the BadAzz Carb.
3. Screw the 45degree elbow into the carb and install a sealing washer and bushing. My carb didn't have a bushing in it when I received it so I had to make one out of a piece of 3/4" PVC pipe. The sealing ring and vent elbow came from a Pacco carb I had lying around.
Continued..............
Nice job!! Love the air cleaner, where did you get it??? How do you like the performance, mine rocked!!
Now on to the choke assembly. All the carb comes with is the boot on top, the choke plunger and spring. I made this assembly until the choke cable I ordered comes in.
1. Remove the top from the BadAzz carb.
2. You'll need an 8d x 2.5" finish nail, two radio control car linkage collars, a small washer and something to use as a handle. I used a Losi Servo arm(get at your local r/c car dealer/hobby shop) a standard servo arm will work and the hobby shop or somone you know who's into radio control probobly has a bunch of them.
3. Machine the nail down so that it fits into the plunger and then slide the spring over the nail and onto the plunger. Put the plunger assembly up into the carb top so the nail sticks out the top.
4. Slide the washer and collar onto the nail and temporarily install the top back into the carb(installing the slide isn't neceassary). This will allow the plunger to properly seat against it's bore and insure you don't set the bottom collar at the wrong height. Pulling up on the nail (but not so much as to pull the plunger from the bottom of the bore) snug the collar and washer against the rubber boot and tighten the set screw on the collar.
5. Slide on your handle and snug the top collar against it tightening the set screw. BE SURE TO USE LOCKTITE ON THESE SET SCREWS. Cut the excess nail from above the collar.
6. Pull up and hold for choke
7. Remove the top from the carb and there's your competed choke assembly.
Continued...........
Last edited by banzai660r : 11-22-2004 at 07:50 PM.
6. Remove your maifold and drill, bore or grind it out to 17mm. Manifold is pictured but not bored out in this pic.
7. Install the assembled carb top, spring and slide onto the throttle cable.
8. Install the carb body assembly onto the manifold and tilt to the right side of the bike(leave the pinch screw loose for now)
9. Install slide, choke and carb top onto carb body.
10. Install and tighten screws.
11. Straighten the carb, tighten the pinch screw and install the fuel line. The fuel nipple is smaller than 1/4" so I used smaller line from the filter to the carb but you can use the rubber bushing off the fuel nipple of the stock carb.
12. Don't forget (like me) to install the overflow tube
---------Once I get the carb tuned I'll update here. Hope this helps those of you who take advantage of BadAzzs' great deal on the carb.
Great job. This deserves a sticky. Also, make sure to submit this as a how to. Send a PM to the admin to request it as a how to. Its a great writeup.
-E
Quote:
Originally Posted by banzai660r
6. Remove your maifold and drill, bore or grind it out to 17mm. Manifold is pictured but not bored out in this pic.
7. Install the assembled carb top, spring and slide onto the throttle cable.
8. Install the carb body assembly onto the manifold and tilt to the right side of the bike(leave the pinch screw loose for now)
9. Install slide, choke and carb top onto carb body.
10. Install and tighten screws.
11. Straighten the carb, tighten the pinch screw and install the fuel line. The fuel nipple is smaller than 1/4" so I used smaller line from the filter to the carb but you can use the rubber bushing off the fuel nipple of the stock carb.
12. Don't forget (like me) to install the overflow tube
---------Once I get the carb tuned I'll update here. Hope this helps those of you who take advantage of BadAzzs' great deal on the carb.
It's snowing here so I won't have a chance to ride it for a while but I can get it close to tuned on the bench. Those of you who have installed the carb and got it running what jets are you using? What is your a/f screw set at? What is your clip position on the needle?
It's snowing here so I won't have a chance to ride it for a while but I can get it close to tuned on the bench. Those of you who have installed the carb and got it running what jets are you using? What is your a/f screw set at? What is your clip position on the needle?
Banzai !!!!!!!!!!!
At 2700 ft elevation I am running the largest jet, with the needle as high in the carb as it can be and the mixture screw set right where it was as shipped
My guy out in new zealand who tests my products out told me i need to get a bigger jet. He tested the carb with the bike and he only has his squish set and heat wrap on his pipe + a 7t front pinion and hes hitting up to 60mph.
hes using the biggest jet so i may have to come up with some more jets for the carb
put the needle clip all the way at the bottom towards point and keep the jet thats in it when you get it. im going to have bits on my site for 5 bux that you can tap the jets to make them bigger
put the needle clip all the way at the bottom towards point and keep the jet thats in it when you get it. im going to have bits on my site for 5 bux that you can tap the jets to make them bigger
Any word on the bits or on larger jets?? I haven't had any luck finding bits that are larger than .080. I finally got a chance to move the needle clip down and the bike fired up and revved pretty clean(on stand). Unfortunately theres 8" of snow on the ground and it's three below with the wind chill. I won't be able to test for a couple more months. I hope you've got some jets or bits available by spring.
Any word on the bits or on larger jets?? I haven't had any luck finding bits that are larger than .080. I finally got a chance to move the needle clip down and the bike fired up and revved pretty clean(on stand). Unfortunately theres 8" of snow on the ground and it's three below with the wind chill. I won't be able to test for a couple more months. I hope you've got some jets or bits available by spring.
Banzai !!!!!!!!!!
I have .09, .10. Ill try to have them on the site tommorrow im just waiting on my cable to hook my camera to pc
I dont think you will need a choke but that is my question too? It would be nice if i could switch back and fourth between 17 and 14 for comparison? but it sounds like Id need to modify the plastic gasket ring on the manafold Anyone noticed a big difference? about the larger jets Id rather be runnin rich than too lean!!
you just have to modify the collar thats on the stock carb to fit inside new collar. If you wanted to go back you could always use a little teflon tape. if you need a choke just hold the back end of you bike up with the throttle open for a couple seconds then let it down and voila..or you can always put your hand over the filter?
.
but I can get it close to tuned on the bench. Those of you who have installed the carb and got it running what jets are you using? What is your a/f screw set at? What is your clip position on the needle?
