3000psi and falling
Zone Head
Posts: 848
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posted May 02, 2011 10:13 PM
Carb guys, Vulcan 500 tuning help needed
Any of you guys good with carbs and tuning?
I am stumped on this one, im working on a 02 Vulcan 500. it was brought to me not running, lots of gas in oil, carbs flooding, old fuel ect. I removed and cleaned the carbs and did what needed done to the rest of the bike and fired it up, started easy, idles nice, reves nice but when I hold the throttle in neutral at about 1/8 to 1/4 throttle after a second or so its starts loading up and puffing dark smoke along with the motor bogging and sputtering untill i open the throttle past 1/4 or return to idle.
Everything appears stock, all vacume hoses are in good shape, fuel is good clean and fresh, spark plugs are new but becoming carbon fouled, good spark, good battery and charging system voltage.
It seems to run fine with the exception of being WAY to rich in the 1/8th to 1/4 throttle range.
Any help or direction would be appreciated!
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08 ZX14, 2010 Persimmon Red bodywork.
Flies pulled, 16-42, BMC street, 8" extensions, drag shock, cut pan, Cycle Concepts Drag Pack and springs, muzzy m14 w/ oval can, lowered, Shinco usoft rear, pcv with autotune, leightweight Shori 18ah battery, throttle meister. 500lbs at bandimeres scales with half tank of juice.
  
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MJ
Zone Head
Posts: 560
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posted May 03, 2011 12:42 AM
Is it spitting gas out of the carb bowl overflows? Sounds like it needs a new needle and seat in at least one if not both carbs. And make sure those plastic floats are actually floating...they have a habit of cracking and filling up with gas over time, which will make the bike so rich it won't want to run much at all.
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LAB3
Needs a job
Posts: 2977
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posted May 03, 2011 12:52 AM
 Edited By: LAB3 on 3 May 2011 08:54
Did you look at the the needle and seat? The fuel needle that is attached to the float will get a indention (ring around the point) so it does Not shut off ALL fuel flow when the float bowl is full. It's like the float is adjusted to high and fuel would run out the over flow vent tube or in this case into the cylinder and low RPM..... just a guess. If too lean look for pin holes the vacuum diaphram that raises the the slide, check this too on all CV carb jobs. Pull the main jet and the brass Main jet nozzle (main jet screws into this)and look at the holes drilled on the sides too. I always remove Everything that can clog up from old gasoline.
EDIT
MJ beat me as I was typing about the needle :-)
Louis
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3000psi and falling
Zone Head
Posts: 848
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posted May 03, 2011 08:27 AM
Edited By: 3000psi and falling on 3 May 2011 16:51
During the rebulid I replaced both seats, inspected the floats, and set the correct float height. I have used the clear hose method to check for proper fuel level in each carb while running and off (was at the correct height). The carbs are not overflowing fuel, vacuume diaphrams are flawless. Carb sync is spot on, and evey jet, hole, part is spotless clean, I did a full teardown and cleaning of these carbs 3 times now.
Question, at idle is the slide needle supose to completely seal off the jet or not?
***while running if I plug off the carb vent tube with my thumb, the motor runs perfect through the whole rpm range, but dies from fuel starvation after a few seconds.
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08 ZX14, 2010 Persimmon Red bodywork.
Flies pulled, 16-42, BMC street, 8" extensions, drag shock, cut pan, Cycle Concepts Drag Pack and springs, muzzy m14 w/ oval can, lowered, Shinco usoft rear, pcv with autotune, leightweight Shori 18ah battery, throttle meister. 500lbs at bandimeres scales with half tank of juice.
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WARBIRD
Needs a job
Posts: 2739
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posted May 03, 2011 12:40 PM
Edited By: WARBIRD on 3 May 2011 20:41
3000, it sounds like your jet needle (that is what the parts fich calls it) is missing. This sits right in the venturi on top of the emulsion tube. The fich calls that the "holder, needle jet". They fall out sometimes and people don't notice it is gone. The needle slides down through this and if it is gone ...... as soon as the slide moves up ( 1/8 throttle or so ) the fuel just gushes into the venturi because the hole around the needle with this part missing is much to large.
I hope the img link works. The part that may be missing is # 16017-1376 It presses into the carb body above the needle jet holder....emuslion tube.
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I'd Rather Be Roadracing.
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WARBIRD
Needs a job
Posts: 2739
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posted May 03, 2011 12:47 PM
Here is the whole page...........the fich has funny names for parts sometimes........ 
http://www.cheapcycleparts.com/model_years/1735-kawasaki-2002-vulcan-500-ltd-en500-c7/assemblies/23720
.
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I'd Rather Be Roadracing.
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3000psi and falling
Zone Head
Posts: 848
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posted May 03, 2011 01:49 PM
Thanks Warbird, I did not see this piece when I cleaned the carbs, I think you on to something! I will pull the carbs again and look for this.
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08 ZX14, 2010 Persimmon Red bodywork.
Flies pulled, 16-42, BMC street, 8" extensions, drag shock, cut pan, Cycle Concepts Drag Pack and springs, muzzy m14 w/ oval can, lowered, Shinco usoft rear, pcv with autotune, leightweight Shori 18ah battery, throttle meister. 500lbs at bandimeres scales with half tank of juice.
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WARBIRD
Needs a job
Posts: 2739
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posted May 03, 2011 02:52 PM
You are welcome 3000.......... If you can get to the top of the carbs with them on the bike, you can just remove the covers, pull the slides out and you will see if that part is missing. There could be only one of them missing or both. If it is one you will notice the difference looking down the carbs where the slides sit right away.
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I'd Rather Be Roadracing.
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LAB3
Needs a job
Posts: 2977
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posted May 03, 2011 02:57 PM
Good eye Warbird...................................... Learn that the "Hard Way" ?? :-) I did not even think about that making the engine act that way.
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billeason
Zone Head
Posts: 711
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posted May 03, 2011 05:51 PM
Check to make sure you have p/n 16009 seated correctly in p/n 16126 and that p/n 16007 is sitting down over 16009 all the way.
If you find that warbirds diag wasn't the problem then double check the above.
If that needle isn't seated into the slide ( and its easy to get it cocked ) it will produce your symptoms ...........
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bill eason
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3000psi and falling
Zone Head
Posts: 848
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posted May 05, 2011 10:01 AM
16017 was missing from both carbs. Ordered replacements. Thanks everyone, you guys know your stuff!
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08 ZX14, 2010 Persimmon Red bodywork.
Flies pulled, 16-42, BMC street, 8" extensions, drag shock, cut pan, Cycle Concepts Drag Pack and springs, muzzy m14 w/ oval can, lowered, Shinco usoft rear, pcv with autotune, leightweight Shori 18ah battery, throttle meister. 500lbs at bandimeres scales with half tank of juice.
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WARBIRD
Needs a job
Posts: 2739
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posted May 05, 2011 11:29 AM
You are welcome 3000.............
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I'd Rather Be Roadracing.
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WARBIRD
Needs a job
Posts: 2739
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posted May 05, 2011 11:32 AM
quote:
Good eye Warbird...................................... Learn that the "Hard Way" ?? :-) I did not even think about that making the engine act that way.
Heh heh heh................yes Louis, for sure the hard way. Luckily for me it was an ATV so removing and replacing the carb a zillion time's was easier than a set of two or four on a street bike........... 
.
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I'd Rather Be Roadracing.
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WARBIRD
Needs a job
Posts: 2739
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posted May 14, 2011 12:28 PM
Did you fix that Vulcan?
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I'd Rather Be Roadracing.
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3000psi and falling
Zone Head
Posts: 848
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posted May 14, 2011 04:31 PM
Yep, its owner rode off with it happy as could be, thanks again for the direction!
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08 ZX14, 2010 Persimmon Red bodywork.
Flies pulled, 16-42, BMC street, 8" extensions, drag shock, cut pan, Cycle Concepts Drag Pack and springs, muzzy m14 w/ oval can, lowered, Shinco usoft rear, pcv with autotune, leightweight Shori 18ah battery, throttle meister. 500lbs at bandimeres scales with half tank of juice.
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WARBIRD
Needs a job
Posts: 2739
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posted May 16, 2011 01:19 PM
Good deal........... 
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I'd Rather Be Roadracing.
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