Carb Cleaning....almost - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 2Likes
Reply
 
LinkBack Thread Tools
post #1 of 43 (permalink) Old 7-29-2019, 12:14 AM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Carb Cleaning....almost

So, I figured I'd take my carbs apart and clean them this evening... unfortunately it seems the last person to mess with them or attempt to mess with them mangled the hell out of the screws. I went through all my bits and found some that were a snug fit for 6/8 of the screws. The other two are pretty much completely rounded out and I'll have to go get a tool so I can take them out.

Hopefully next week I can finish taking them apart and cleaning them.
Attached Images
File Type: jpg IMG_20190728_205950_1564373665260.jpg (218.3 KB, 25 views)
File Type: jpg IMG_20190728_210024_1564373680336.jpg (193.1 KB, 21 views)
Selttus is offline  
Sponsored Links
Advertisement
 
post #2 of 43 (permalink) Old 7-29-2019, 12:34 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
routine stuff....dremel a slot,....use a standard screwdriver or impact driver with appropriate tip

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
post #3 of 43 (permalink) Old 7-29-2019, 5:36 PM
Senior Member
 
Davenay67's Avatar
 
Join Date: Dec 2018
Location: Lisle, IL
Posts: 149
 
It's interesting that the float bowl screws are mangled, indicating that the PO(s) have been into the carbs, but the A/F tamper caps are still in place. Curious to see what the insides of those carbs look like....

2007 Kawasaki EX-500 Ninja
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
Davenay67 is offline  
 
post #4 of 43 (permalink) Old 7-29-2019, 6:21 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
you should deeply consider Custom Carb Service # 68 https://www.ex-500.com/50-carburetor...bset-68-a.html

would save you a world of headache...bolt on, set your idle and go

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
post #5 of 43 (permalink) Old 7-29-2019, 7:32 PM
Senior Member
 
Saabnut's Avatar
 
Join Date: Feb 2012
Location: Santa Rosa, CA
Posts: 2,313
 
Quote:
Originally Posted by Davenay67 View Post
It's interesting that the float bowl screws are mangled, indicating that the PO(s) have been into the carbs, but the A/F tamper caps are still in place. Curious to see what the insides of those carbs look like....
I'd say the untouched caps and stripped screw are a good indication a prior owner ATTEMPTED to mess with the carbs but failed in stellar fashion to even get inside.

1990 EX500 - 142,000 miles as of August 12th, 2019
1993 Ducati 900SS - The real canyon carver
2002 EX500 - Undergoing a full restoration
Saabnut is offline  
post #6 of 43 (permalink) Old 7-29-2019, 9:14 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by ducatiman View Post
you should deeply consider Custom Carb Service # 68 https://www.ex-500.com/50-carburetor...bset-68-a.html

would save you a world of headache...bolt on, set your idle and go
I would....but I like to learn. Which is why I went for the parts you sell instead of the full package. Much appreciated either way though. I'll post pics after I get everything installed.
Selttus is offline  
post #7 of 43 (permalink) Old 7-29-2019, 10:26 PM
Senior Member
 
Join Date: Oct 2017
Location: S.F. Bay Area
Posts: 124
 
Note to do self-service carb-cleaning, you’re gonna need to buy some equipment:

- complete set of JIS screwdrivers (none of those screws are philips)
- ultrasonic cleaner
- caustic radioactive EPA-banned solvents
- guitar wire in numerous gauges
- micro soda blaster
- 10000psi compressor

You!ll also need to practice on several thousand carbs to have experience necessary if you want factory-fresh clean carbs.
DannoXYZ is offline  
post #8 of 43 (permalink) Old 7-30-2019, 12:12 AM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Hmmm... But what if I want some back yard you did an okay job cleanish Carbs? I mean my Dad always cleaned his own on his workbench back home with nothing too fancy and he still rides his v65 Sabre around.
Selttus is offline  
post #9 of 43 (permalink) Old 7-30-2019, 12:14 AM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Doesn't look too bad so far, jets were super clean on this side....
Attached Images
File Type: jpg IMG_20190729_202915_1564460005995.jpg (230.2 KB, 18 views)
Selttus is offline  
post #10 of 43 (permalink) Old 7-30-2019, 10:14 AM
Senior Member
 
Davenay67's Avatar
 
Join Date: Dec 2018
Location: Lisle, IL
Posts: 149
 
Quote:
Originally Posted by Selttus View Post
Doesn't look too bad so far, jets were super clean on this side....
Seems pretty clean from the surface at least. Junk can still possibly exist in the passageways in the carb body.

Was there a specific reason for cleaning the carbs (poor running, bad starting, etc), or was it just a case of it being a maintenance exercise you wanted to perform?

2007 Kawasaki EX-500 Ninja
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
Davenay67 is offline  
post #11 of 43 (permalink) Old 7-30-2019, 11:38 AM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by Davenay67 View Post
Quote:
Originally Posted by Selttus View Post
Doesn't look too bad so far, jets were super clean on this side....
Seems pretty clean from the surface at least. Junk can still possibly exist in the passageways in the carb body.

Was there a specific reason for cleaning the carbs (poor running, bad starting, etc), or was it just a case of it being a maintenance exercise you wanted to perform?
It was running kind of poor, a bit hard to start and would die when you stopped. I'm also waiting on a spark plug tool to come in so I called my dad and he suggested cleaning the carbs. The guy I got it off of wasn't very mechanically inclined so I figured I'd clean everything and go through the maintenance list.

The plugs are fairly neglected, it looks like the guy never wanted to deal with buying the socket to get them out. They have a bit of corrosion on them and they're the OEM plugs so no idea when they were last changed. When I get home I'll post a picture of that as well and maybe start a different thread in troubleshooting or general just to post updates.

The bike was $320 and $180 for registration/plates so I wasn't exactly expecting this to be a walk in the park. It's more of me trying to get back into working on things I actually enjoy and learning something along the way. I work on radars, pumps and other miscellaneous electronics all day and this is a nice "break" from that.

Last edited by Selttus; 7-30-2019 at 12:01 PM.
Selttus is offline  
post #12 of 43 (permalink) Old 7-30-2019, 11:51 AM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
https://photos.app.goo.gl/bhYuvxyu7P5bz8HGA

I have a longer video somewhere else, I'll post it if I can find it.
Selttus is offline  
post #13 of 43 (permalink) Old 7-30-2019, 11:51 AM
Senior Member
 
Davenay67's Avatar
 
Join Date: Dec 2018
Location: Lisle, IL
Posts: 149
 
Quote:
Originally Posted by Selttus View Post
Doesn't look too bad so far, jets were super clean on this side....
You mention clean jets. I'm assuming all of the holes are clean and clear? On a neglected bike, it can be a worthwhile expense to simply replace the jets, but cleaning is certainly possible.

Beyond clean carbs, the float heights need to set accurately, and then the carbs need to be synchronized to each other. Take each step in sequence and see how the bike runs after this work.

2007 Kawasaki EX-500 Ninja
2001 Honda VFR 800
2000 Kawasaki KDX 200
1999 Ducati 996 BiPosto
Davenay67 is offline  
post #14 of 43 (permalink) Old 7-30-2019, 12:06 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by Davenay67 View Post
Quote:
Originally Posted by Selttus View Post
Doesn't look too bad so far, jets were super clean on this side....
You mention clean jets. I'm assuming all of the holes are clean and clear? On a neglected bike, it can be a worthwhile expense to simply replace the jets, but cleaning is certainly possible.

Beyond clean carbs, the float heights need to set accurately, and then the carbs need to be synchronized to each other. Take each step in sequence and see how the bike runs after this work.
Yes the holes were completely clear on the one side so far, checking the other side when I get back home.

I'm actually waiting on tools to do some of these things at the moment. I just got back from Japan and my tool chest is in Indiana so I've been ordering parts/tools slowly while waiting on my Dad to ship my stuff from back home.

I was going to build one of the diy manometers and try doing the carb synch this Friday. I've never really worked on bikes before so I've just been following the Haynes manual thus far, I'll look up float hieght part when I get home.

Last edited by Selttus; 7-30-2019 at 12:11 PM.
Selttus is offline  
post #15 of 43 (permalink) Old 7-30-2019, 12:15 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
All valid reasons to service. In addition, depending on mileage consider a valve clearance check. Tight exhaust valves could very well be contributory to your hard starting condition.

Whats the year and mileage?

And re carb clean...drill and pull the anti tamper caps over the pilot screws, remove screw/spring/washer/oring. That orifice is important part of the pilot circuit (but you knew that) and needs "attention".....the replacement tiny orings will be in your kit.
Reassemble at 2.5 turn starting point....when bike is running and full op temp...set each side finding the "sweet spot", but sych first if you can (bench or manometer).

Valve adjust, carb clean, synch, proper pilot screw set......and with all the other tuning crap (spark plugs, air filter, blah blah)
you'll have yourself a fine running 500. BTW...disassemble and clean the insides of the spark plug caps (lug, springs, resister inside each) and "trim" the wires if need be. You understand what I'm referring to here?

Goal...instant start at touch of button, smooth unwavering idle set to your chosen RPM, good response to throttle input, prompt return to idle after releasing throttle. Good time to lube throttle and clutch cables...setting freeplay on each.

I'm beat after all this...whew! All the rest up to you now....have fun.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
post #16 of 43 (permalink) Old 7-30-2019, 12:23 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by ducatiman View Post
All valid reasons to service. In addition, depending on mileage consider a valve clearance check. Tight exhaust valves could very well be contributory to your hard starting condition.

Whats the year and mileage?

And re carb clean...drill and pull the anti tamper caps over the pilot screws, remove screw/spring/washer/oring. That orifice is important part of the pilot circuit (but you knew that) and needs "attention".....the replacement tiny orings will be in your kit.
Reassemble at 2.5 turn starting point....when bike is running and full op temp...set each side finding the "sweet spot", but sych first if you can (bench or manometer).

Valve adjust, carb clean, synch, proper pilot screw set......and with all the other tuning crap (spark plugs, air filter, blah blah)
you'll have yourself a fine running 500. BTW...disassemble and clean the insides of the spark plug caps (lug, springs, resister inside each) and "trim" the wires if need be. You understand what I'm referring to here?

Goal...instant start at touch of button, smooth unwavering idle set to your chosen RPM, good response to throttle input, prompt return to idle after releasing throttle. Good time to lube throttle and clutch cables...setting freeplay on each.

I'm beat after all this...whew! All the rest up to you now....have fun.
I understand a bit and I feel I can figure out what I'm slightly lost on. Most of what you mentioned is already in the manual I've been following under the maintenance section so I guess I can just keep following that. I don't exactly understand the trim part of the spark plug wires, besides it probably involving trimming some wires or something of that nature, but someone has probably posted it somewhere and I'll find it eventually, if not I'll just ask on here.

It's an 04 with 24300 miles on it.

Last edited by Selttus; 7-30-2019 at 12:29 PM.
Selttus is offline  
post #17 of 43 (permalink) Old 7-30-2019, 12:27 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Either way if I screw the carb part up too bad I can always give you some of my hard earned cash have you make it like new right? Or well buy a refurb off you. Only if I really mess up though lol
Selttus is offline  
post #18 of 43 (permalink) Old 7-30-2019, 1:12 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
always at your service if need be, of course, but encourage you to give it your best shot

i'm not inclined to hog your thread, anybody else want to offer advise on trimming spark plug cable ends?

@bpe? (callout to a very experienced participating member here)

and at the 24,000 miles, IS important to check valve clearances (unless done in the last 7500 miles, the Kawasaki suggested service interval )

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

Last edited by ducatiman; 7-30-2019 at 1:16 PM.
ducatiman is offline  
post #19 of 43 (permalink) Old 7-30-2019, 1:15 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by ducatiman View Post
always at your service if need be, of course

i'm not inclined to hog your thread, anybody else want to offer advise on trimming spark plug cable ends?

@bpe? (a very experienced participating member here)
Anyone can hog my thread with all the sound advice they want to give but if you want to give bpe a chance I can wait. Probably need to move this to a different thread anyways as we've gotten away from carbs.
Selttus is offline  
post #20 of 43 (permalink) Old 7-30-2019, 1:19 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
thats ok to leave it here, let the thread wander a bit....all part of your correlated service ...and it'll come back to carbs at some point.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
post #21 of 43 (permalink) Old 7-30-2019, 1:22 PM
Super Moderator
 
ducatiman's Avatar
 
Join Date: Feb 2008
Location: NEW YORK
Posts: 14,012
 
Garage
@bpe a longtime owner, likely to make valid additional suggestions. WORTH the wait.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

Custom Carb Service

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
ducatiman is offline  
post #22 of 43 (permalink) Old 7-30-2019, 1:30 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
True carbs will definitely be making an appearance again on Friday.
Selttus is offline  
post #23 of 43 (permalink) Old 7-30-2019, 1:52 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
I found some vacuum gauges in one of my boxes of tools that actually made it, so no need to build one now.
Selttus is offline  
post #24 of 43 (permalink) Old 7-30-2019, 3:20 PM
bpe
Senior Member
 
bpe's Avatar
 
Join Date: Mar 2015
Location: Atlanta,GA
Posts: 5,514
 
Garage
Quote:
Originally Posted by ducatiman View Post
@bpe a longtime owner, likely to make valid additional suggestions. WORTH the wait.
You make my head swell .

I think everyone has pretty much covered everything. This thread may help with what's being said with trimming the spark plug wires.
https://www.ex-500.com/119-basic-mai...nspection.html

And I will add:
You do want to do the valve adjustment before the carb sync. To get an accurate sync.
I think your well on your way, don't hesitate to ask questions.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
bpe is offline  
post #25 of 43 (permalink) Old 7-30-2019, 5:55 PM Thread Starter
Member
 
Selttus's Avatar
 
Join Date: Jul 2019
Location: San Diego, CA
Posts: 30
 
Quote:
Originally Posted by bpe View Post
Quote:
Originally Posted by ducatiman View Post
@bpe a longtime owner, likely to make valid additional suggestions. WORTH the wait.
You make my head swell [IMG class=inlineimg]/images/Ex-500_2016/smilies/tango_face_surprise.png[/IMG].

I think everyone has pretty much covered everything. This thread may help with what's being said with trimming the spark plug wires.
https://www.ex-500.com/119-basic-mai...nspection.html

And I will add:
You do want to do the valve adjustment before the carb sync. To get an accurate sync.
I think your well on your way, don't hesitate to ask questions. [IMG class=inlineimg]/images/Ex-500_2016/smilies/tango_face_wink.png[/IMG]
I actually found your valve adjustment post on another Kawasaki forum that I'll probably use as reference along with my Haynes manual.
bpe likes this.
Selttus is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome