Stage 1 Jet Kit Install procedure
Parts and tools recommended before you start.
Tools:
High quality #2 Phillips magnetic screwdriver
Flat blade screwdriver
Metric Allen wrench set
Metric socket wrench set
Needle Nose Vicegrips
Impact screwdriver
Service Manual
Parts:
Jet Kit
SS Allen screw kit
Read this procedure over several times to make sure
you understand the steps.
1. Using the Service Manual remove the seat, right side plastic cover, and the gas tank.
Disconnect the NEG lead on the Battery.
2. Do the front carb first since it’s the easy one to get at. See Figure 2.
3. Remove the 4 very tight screws that hold top plate on. These screw heads will
strip very easy, so I would use the impact screwdriver. If they strip try cutting
a slot in them and use a flat screwdriver or use the Vicegrips.
Be careful that the spring under the top plate doesn’t pop out and go flying.
4. Carefully pull the slide out of the carb. Mark the top of needle hold down plate so
It can be installed right side up.
5. Remove the 2 small phillips screws down in the slide. Be careful not to have the
needle assy pop out of the slide and go flying.
6. Remove the plastic washer, spring and washer from the needle.
7. Install the new E-clip in the middle groove of the needle. This is the 3rd position
From the top or bottom of the needle.
8. Assemble the new needle, See Fig 1.
9. Using the drill bit supplied drill the vacuum hole out. See Fig 1.
10. Blow any drilling bits out of the slide.
11. Install the needle assy into the slide and holding it down, install the needle hold
down plate. See Fig 1.
12. Install the slide back in the front carb. This can be tricky. Sometime the needle
won’t go back into the needle seat. If that happens try turning the slide, if that don’t
work then remove the rubber snorkel between the carb and airbox. That
will give you access to the needle. Also you can use a small flat long screwdriver
to push the top of the needle down a little and straighten it out so it will go into
the seat. ( you will have to do this for the rear carb or remove the battery and
rear airbox to get at the needle.
13. Make sure the slide is all the way down and the rubber diaphragm is on the carb
correctly.
14. Reinstall the spring and top cover.
Now do the same procedure to the rear carb.
Use the drill to drill the mixture caps after drilling the slides.
See Mixture screw adjustment procedure
Figure 1
Figure 2