Edelbrock Kawasaki KFX400 Bedienungsanleitung

INSTRUCTION SUPPLEMENT FOR 2003-

LATER Suzuki LTZ400 and Kawasaki

KFX400

Removing stock carburetor and cables.

1. Remove seat, front fenders and gas tank.

Make sure fuel petcock is in “ON” or

“RES” position. If it is in the “PRI”

position it will allow fuel through it.

2. Remove throttle cable, (and housing if

installing a twist kit) from throttle housing.

Pay close attention to routing when

removing cable as the new cables will need

too be routed the same.

3. Disconnect choke cable from stock

carburetor before disconnecting it from

handle bar and remove.

4. Remove stock carburetor.

5. Stuff a dry, clean rag into the intake

manifold to keep debris from entering

engine.

6. Remove stock rear head stay from frame

and head.

7. Remove plastic vent box from right side of

frame along with hoses.

Installing the Edelbrock Carburetor and

Throttle Cables

1. Install new rear head stay. NOTE: Start four

frame bolts before inserting larger bolt

through stay and cylinder head. It is

recommended blue Loctite or equivalent be

used on frame bolts. Tighten frame bolts

first, then head bolt.

2. Install large clear hose to upper, rear

pointing barb (hose comes from air boot) on

plastic breather box and secure with clamps.

3. Remove the rubber carburetor alignment

tabs from the manifold using a razor blade or

side cutters. Be careful not to damage

manifold or fingers during this procedure!!

4. Install the throttle cable into the stock

throttle housing. If using a twist kit, install

cables into supplied throttle housing

supplied with kit and place onto clean

handlebar end.

5. Remove the hex pipe plug from the carb cap

using a 11mm or 7/16 wrench. Do not

discard plug, as it will be needed later.

Install the metering adjustment tool included

in the hardware kit. Do not over-tighten as

damage may occur to cap.

6. Install supplied fuel line onto carburetor and

secure with pinch clamp.

7. Install supplied vacuum line onto brass

carburetor vacuum fitting. See Figure 1.

The vacuum fitting will have a black vinyl cap

on it from the factory.

Figure 1,

NOTE: The vacuum line can be left off if the

engine is run while the petcock is left in the

“PRI” position. This may want too be

considered by racers who do not depend on a

reserve. If you choose to do this, the black

vinyl cap must be left on the carburetor vacuum

fitting and the spare cap can be placed over

the vacuum port of the petcock.

8. Remove rag from manifold.

9. Install carburetor into manifold and slip air

boot over back of carburetor. Do not tighten

yet.

10. Route cable(s) under new head stay to

carburetor

11. For thumb throttle applications, install the

throttle cable into the 8:00 position of the

cable wheel and secure with clamp. See

figure 2.

Figure 2.

For twist throttle applications, install the pull cable

(long shoulder on cable) into the 8:00 position and

the return cable end into the 11:00 position of the

cable wheel. Secure cables to cable bracket by

replacing end piece and phillips screw. See figure

Figure 3.

12. Align carburetor as close to vertical as

possible, then tighten manifold and air boot

clamps.

13. Adjust cable until wide-open throttle is

achieved. For thumb throttle minor grinding

of the throttle arm may be necessary to

achieve wide-open throttle. Twist throttle:

Adjust return cable to take up the slack.

Note: When throttle cables are properly

adjusted, there should be approx. 1/8” of

free play in the throttle.

14. After throttle cables have been adjusted the

handle bars should be rotated from full right

stop to full left stop while opening and

closing throttle to ensure smooth operation.

Also check to make sure the cables do not

catch or bind on anything, i.e., hand guards,

stabilizers.

15. Install Remote Idle Cable into threaded tab

on top of carburetor. Refer to main

instruction manual for remote idle cable

installation and adjustment.

16. Install stock breather box to right side of

frame and reconnect stock hoses to cylinder

and valve cover. Connect new clear hose to

air boot.

17. Install fuel tank. Trim fuel line to desired

length and secure to petcock with provided

pinch clamp. Trim vacuum line to desired

length and connect to small vacuum port on

backside of petcock. NOTE: If the vacuum

line is not installed to the carb and

petcock, fuel will only flow in the “PRI”

position on the petcock.

18. Turn fuel petcock to “PRI” and check for

leaks.

19. Open throttle 3-5 times to prime accelerator

pump. Do not open throttle any more than

5 times as this may flood engine!!

20. Once pump is primed, engage starter

without opening throttle. If Motor will not fire,

slowly open throttle until it starts. If it does

not start within 5-7 seconds, disengage

starter and pump throttle 2-3 more times and

repeat starting process.

NOTE: If flooding occurs, slowly open

throttle to wide open and hold. With

throttle still open, hold decompression

lever and kick motor through 5-10 times.

Release throttle and decompression lever

and proceed with normal starting

procedure.

For any questions regarding tuning or

installation of Edelbrock products, please

call our toll free tech line M-F 8:00am-12:

30pm, 1:30pm-5:00pm PST.

877-888-7504 ext.2.

Edelbrock #3157 (thumb) and #3158

(twist) Suzuki LTZ400 and Kawasaki

KFX400 Carburetor Specifications

Bore Size: 38mm Tall X 34mm Wide

Needle: 17E @ 12 Clicks

Accelerator Pump Bypass: 2 ¼turns out

Alternate Needles: 15E, 19E

Replacement Cables: #9354 Thumb Cable

#9355 Twist Cables, pair

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