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Kawasaki KLE500-B1 2004 Service Manual.doc
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Caution

During carburetor disassembly, be careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm.

• Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of turns counted during dis­assembly.

Топливная система3-15

Carburetors

• Turn the carburetor body upside-down, and drop the nee­dle jet [A] into place so that the smaller diameter end [B] of the jet goes in first.

• Carefully screw in the needle jet holder. It will seat against the needle jet, pushing the end of the jet into the carbu­retor bore.

Caution

Do not force the needle jet holder [A] and main jet [B] or overtighten them. The needle jet or the car­buretor body could be damaged requiring replace­ment.

• Slip the jet needle through the hole in the center of the vacuum piston, and put the spring seat [A] on the top of the needle. Turn the seat so that it does not block the hole [B] at the bottom of the vacuum piston.

  • Install the carburetor top cover.

  • Turn in the pilot screw fully but not tightly, and then back it out the same number of turns counted during disassem­bly.

  • When removing the coasting enricher system, unscrew the mounting screws [B] and remove the air cut valve cover [C], spring [D], O-ring [E] and diaphragm [F].

Right Carburetor [A]

Torque - Air Cut valve Cover Screws: 1.0 N·m (0.10 kgf·m, 9 in·lb)

Carburetor Separation/Assembly

  • Read the WARNINGS in the Carburetor Removal.

  • Remove the choke synchronizing stay spring [A].

  • Remove the choke synchronizing stay screws [B] with ny­lon washers, and remove the stay [C].

3-16 Топливная система

Carburetors

• Remove the upper carburetor mounting screws [A] and stay [B].

○Remove the fuel supply pipe connected both carburetors.

• Remove the vacuum hose [C] connected both carbure­ tors.

• Remove the lower carburetor mounting screws [A] and stay [B].

  • Inspect the O-rings [A] of fuel supply pipe.

  • If they are damaged, replace the O-rings.

  • The center lines of the carburetor bores must be parallel both horizontally and vertically. If they are not, loosen the mounting screws and align the carburetors on a flat surface. Retighten the mounting screws.

  • After assembling the choke mechanism, check to see that the starter plunger lever slides from side to side smoothly without abnormal friction.

Caution

Fuel mixture trouble could result if the starter plunger does not seat properly in its rest position after the choke lever is returned.

Топливная система 3-17

Carburetors

• Visually synchronize the throttle (butterfly) valves. OCheck to see that the throttle valves open and close

smoothly without binding when turning the pulley. OVisually check the clearance [A] between the throttle valve and the carburetor bore in each carburetor.

* If there is a difference between the throttle valves, turn the balance adjusting screw [B] to obtain the same clearance. Do not remove the atmospheric pressure hose.

Carburetor Cleaning

WARNING

^

Clean the carburetors in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash -point solvents to clean the carburetors.

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