Is this the secondary main jet?

[sham]

Hi, so still haven't managed to get the carb right, but while I was at it I thought I'd rejet it for pods seeing as the air filter element doesn't seem to be in production anymore.


I found some sizes from kzrider which seems to work - the link I posted on my build thread.


The plan is to rejet the following:


Keihin CV32


Jet Original Size New Size
Primary #68 #70
Secondary #98 #125-130


Question is a dumb one - according to the parts manual I believe the highlighted part of the image is the main jet (secondary). Is this correct? Cos I can't seem to remove it from the needle jet holder, and I'm worried about using excessive force. Any suggestions?

 

[sham]

Attached is the carb diagram. I believe the secondary main jet is number 92062A/B/C/D/E. See how its separate from the needle holder 13091?

 

[CresentSon]

Yup, looks like a main jet. The only advice I can give is put a wrench on the 'needle jet holder', and a nice broad flathead on the jet. Mix in some penetrating oil and elbow grease.

 

[crazypj]

Yes
It will come out pretty easy with a flat screwdriver and 8mm box end to hold Hex
If slot starts getting chewed up, grab jet with a pliers

 

[skatetheame]

Yeah I had to use an 8mm wrench and some vice grips to get the original mains out of the needle jet holders.

 

[crazypj]

BTW, 125 sec main will be way too big

 

[sham]

Thanks guys - the jet is still stuck, so I might douse it in brake cleaner and let it sit for a bit. Things are complicated by the torn cartilage in both my wrists, which render my hands pretty useless when it comes to anything forceful...the slot is getting chewed up, but I don't want to use pliers yet as I can't find a replacement jet incase all this does go wry...

A question on the use of brake cleaner - I know this seems to be common practice, to soak these jets in this stuff, but I took off the brass or nickel or whatever layer last time round on my drain screw when I used white vinegar. Now, I know that vinegar is acidic and brake cleaner is a different thing, but is there a chance I might alter the jet holder by doing this (using brake cleaner or clr equivalent)?

In regards to the sizing, it seemed most people on the kz forum ended up using 130 secondary main and left it at that. The original recommendation was to also run a 70 primary main, so I thought I'd order all three and see which works better?

 

[crazypj]

What size is the jet your trying to remove?
If it's not the right one, don't worry about damaging it, no-one buys used jets and your not going to use it either.
Brake cleaner is pretty worthless as carb cleaner, use WD40 as 'release oil'
White vinegar probably leached some of the zinc out of the brass, the plugs and screws in carburettors are very rarely plated
Kei-Hin jets are easily available.
If your working on a KZ400, it's only 22cc larger than my 378cc Honda motor. (which is 22cc larger than stock CB360)
I use 112.5 secondary main so I still say 130 is way oversize, maybe they don't know or care if it's loosing a 'lot' of power?
360 carbs need more modification than just swapping secondary mains, pretty sure Kawasaki carb needs similar modification to work properly

 

[sham]

The jet is a 98 - the original size to be used with an air box.

As I'm considering pods and have a friend going to America, I thought I'd rejet and those were the sizes people had been using.

The bike itself is only a 250cc, so smaller than yours, which I assume means I should also be having a smaller secondary main? I might buy something around the 110s then just in case. Assuming that the size of the other primary and pilot jet also influences this, can I ask what you might be running there? The pilot jet is around 42 for memory - will have to recheck.

The WD40 didn't work, so I now have it sitting in the freezer - hoping the cold will cause the metal to contract a bit, and for the variation in size to loosen things up? Is a "stuck" secondary main jet a possible cause for the bike not starting? Fuel is not going through the carb, which is why I started playing with float heights (still not right - thought I'd wait till I finished rejetting now).

Seeing as I've now found the correct air filter element, what are people's thoughts on going for the pod? I initially set out to do this only because I thought kawasaki stopped making them, but it had in fact been superseded, but the number wasn't updated.

 

[crazypj]

Cool, thought you had a 400 but wondered about 32mm CV carb
What bike do you have 250 twin or single?
Also, where are you in the world?

 

[sham]

Its just a single, based in Sydney - far away from cheap and accessible parts...

 

[crazypj]

Ah, that explains a lot
130 should be too big but 107.5 will be too small for a 250 cylinder

 

[sham]

Ah ok - I really don't understand much about jetting. I am looking for stuff to read up on it now, but seeing as I have a friend going over to the states for 2 nights (work) I thought I would quickly order some stuff and get it back asap.

I had a change of mind regarding this whole carb (fuel level) and jet problem - decided to disassemble and start again. Having watched TT3D: Closer to the Edge last night, I came away thinking I want to actually get as much out of this bike/experience rather than just making it "work" again...so yeh...

Below is an image of my efforts - much more thorough than the first time I think. New gaskets should be coming as well, along with the carb holder

The damn main jet still doesn't come off, despite much plier-ing, soaking etc...anyone have any ideas? And I wasn't able to remove the throttle shaft, there is a strange metallic washer on the other end which I'm not sure how to remove...has anyone had any experience with this?

I disassembled according to this: http://users.rcn.com/kochc/moto/carb/carb.html

 

[crazypj]

Now that is tripped for cleaning ;D
Is the needle jet removable or part of the emulsion tube?
If it's still in there, try pressing on it from the 'top' with a plastic pen (throttle slide side)

 

[sham]

The needle is removable but I'm worried about damaging the diaphragm. The disassembly information only says to pull out the vacuum piston with the diaphragm, but seeing as the gasket around the float bowl had to be pried off with a screwdriver I definitely don't want to be facing that - any tips? The slider doesn't seem to be moving that smoothly, and definitely isn't moving evenly (the spring rebounds towards one side before straightening out).

Definitely more annoyed about the jet needle holder at the moment. Any other tips for getting the main jet out?

Also, the circlip holding down the jet needle also resembles the one on the end of the throttle shaft (pictured) - how do people usually remove this?