DIY Shimming the carb needles.

[Jiu Jitsu Player]

#4s. Maybe the washers are the problem. I have the CA version btw so I double checked the hoses in your DIY and the 3 additional ones. At first I forgot the hose underneeath the tank to the fuel sender but after connecting that one I still found I had the same problem.

[kkim]

#4 or 4mm?

[Jiu Jitsu Player]

#4

[kkim]

that's the correct ones.

worst case, put everything back the way it was and see if the problem disappears. if the problem is still there, either something is damaged or not put back correctly.

if you're a gambler, you can take one shim off each needle and see if that helps, instead.

[Jiu Jitsu Player]

I noticed the fuel sender hose had a crimp in it the way it was positioned. I took off the tank and repositioned it to see if there is any change. Going for a test run now and Ill let you know.

[Jiu Jitsu Player]

Ok I still have the same problem. It just sputters in 1st never getting above 1k. I shut it off and started it in neutral and revved it and finally it went up to about 7k so I clicked it into 1st and rode home. It's probably a washer problem. The guy probably told me they were #4 but they're really 4mm.

[Sound Wave]

iirc, the #4's should be a relatively close fit around the needle.
also, you could measure the ID of the washer. it should be really close to 3 mm if it is a #4. i forget what a #4 exactly measures. i posted it up somewhere on this forum.

[kkim]

chris, take a look at post #233... which of those pictures does yours look like?

[Jiu Jitsu Player]

Ok I think they're 4mm not #4. They look like the first picture. Is the plastic part inside the spring supposed to fit over the washers? The washers I have do not fit inside this part. I'm assuming that this is what the problem is.

[kkim]

yep, the plastic is supposed to fit over the washers. you def got the wrong size.

[Sound Wave]

well, at least it is a simple fix. humbug part is that you gotta take everything apart again.

[Viper-Byte]

Yes, the white plastic part on the spring is supposed to fit over the washers. This was my issue and the needles were bouncing around causing the behaviour you are experiencing, except I couldn't even get out the criveway.

[Jiu Jitsu Player]

Thx guys. That explains a lot! On my way to the store to get the right size. I'll let you know how it goes!

[kkim]

obviously, using the proper sized washers is a big problem here.

For future reference... 3MM metric washers or #4 ANSI washers should be used. Don't get the 2 confused. They are basically the same size, but using different standards and hence a different naming convention.

specs for metric 3MM washers...

System of Measurement- Metric
Inside Diameter- 3.2 millimeters
Outside Diameter- 7 millimeters
Thickness- 0.5 millimeters
Size Name- 3


specs for ANSI #4 washers

System of Measurement- English
Inside Diameter- .125 inches
Outside Diameter- .312 inches
Thickness- .031 inches
Size Name- #4


to convert between metric and inches...
http://www.worldwidemetric.com/metcal.htm

[kkim]

Chris... any luck?

[Jiu Jitsu Player]

Ok I got new washers and was able to take it for a test spin. It ran a lot smoother in the lower gears. It almost felt like I gained an extra gear. 1st felt like 2nd etc. The bike just feels way more responsive. I also pulled the snorkel once I got her running pretty good and it feels like a whole new bike. The problem was definitely the washers. Once I swapped them out it started running like a champ!I haven't really gotten a chance to open her up past 3rd gear since I had to go somewhere and ran out of time to test it. Ill take it out when I get home and let you guys know. So far though its running way better than before. THX for all the help guys.
Posted via Mobile Device

[Sound Wave]

cool beans. glad to hear you solved your problem.

[miks]

Good going Chris, hope the bike runs without any hiccups.

[Buffalony]

Chris. Was this with 2 washies? What exhaust? Still stock?

[kkim]

cool... Chris' problem is fixed.

Tim how are you doing with yours?

[Nemy]

yup yup. All done on my end too. Since the stores were closed, I fab'd my own smaller washers from the 4mm But they fit and all revs are nice and smooth again

Specs: leovince slip on, snorkel NOT removed, and 2 washers each.

Thanks again for the help guys.

[kkim]

cool... now take the snorkel out.

[Nemy]

Originally Posted by kkim

cool... now take the snorkel out.

lol NEVER!!! My fingers are still numb from removing and reinserting it! It just made my exhaust sound wierd and whiny. Definitely not what I paid for lol

[kkim]

Originally Posted by Nemy

lol NEVER!!! My fingers are still numb from removing and reinserting it! It just made my exhaust sound wierd and whiny. Definitely not what I paid for lol

you paid for sound?

the snorkel removed allows the bike to rev freely to redline. I would think that's what you paid for instead. Personally, I could care less about what it sounds like if removing it enhances the bike's ability to make power.

[Viper-Byte]

IMO, the sound with the snorkel out is much better, it actually sounds like a bigger bike because it has a sort of rumble and the difference in power and response is worth it.

[rookie]

How many washers for stock exhaust and snorkel removed?

[kkim]

best guess... 2.

http://www.ninjette.net/forums/showthread.php?t=9465

[Jiu Jitsu Player]

I'm rolling with stock exhaust (for now), 2 washers, and snorkel out. The bike is definitely alot louder without the snorkel and the extra air intake really makes a difference. I can't wait to get a full system exhaust on!

[Nemy]

Originally Posted by kkim

you paid for sound?

the snorkel removed allows the bike to rev freely to redline. I would think that's what you paid for instead. Personally, I could care less about what it sounds like if removing it enhances the bike's ability to make power.

looks, sound, and performance in a tiny package

Right now she's reving perfectly to redline with the 2 washers in. Plus I would drive myself crazy if I had to listen to a whiny exhaust everyday... esp one that I had to pay extra for lol

[kkim]

Originally Posted by Nemy

Right now she's reving perfectly to redline with the 2 washers in. Plus I would drive myself crazy if I had to listen to a whiny exhaust everyday... esp one that I had to pay extra for lol

lol... cool, enjoy!

[headshrink]

So I'm finally going to try it myself.... I had been planning to do a re-jet, but after considering the cost/benefit potential of this mod, raided the change drawer in my office. I'm currently all stock (no plans to change pipe). I plan to go with 2 washers, as that seems to be what most go with. Although I am curious about the snorkel removal, I really don't want to add noise.
I just ran around to a few different places and only one person had even heard of JIS drivers, and only because one person had asked about them once.... I see them online, but hate to delay projects for stupid things..... Hopefully it won't be an issue.

[Nemy]

If you can't find JIS, I found something in the shape of an S - like an allen key with two ends. The number 2 fit in and I was able to get the rest of the screws off no problem.

[headshrink]

I think I ended up using a Pozidrive bit, this seemed to fit a little tighter. I pressed down and had no problems.

Install seemed to go fairly smooth and I just got back from a test ride. My initial impression is that it is a little livelier off the line and the gears [seemed] a little taller. It was rush-hour, so I didn't have much time or space to play. The weather is changing too, so theoretically this MAY have played a factor in some of the difference from earlier in the day..... we shall see. But hey, so far the best 20 cents I have spent on the thing!

One thing I was concerned about though, is I got to see just how thin the diaphrams are, and one shifted while working on it.... if by chance one didn't seat right, or even tore, what symptoms would I see?

[kkim]

did you yank the snorkel?

[headshrink]

Naw, I didn't.... keeping the noise down.

[kkim]

Originally Posted by headshrink

One thing I was concerned about though, is I got to see just how thin the diaphrams are, and one shifted while working on it.... if by chance one didn't seat right, or even tore, what symptoms would I see?

the bike wouldn't rev properly/smoothly. if your bike is running well, don't worry about it.

[headshrink]

As far as I can tell it is fine then.... should I expect any difference in mpg (even slight)?

[kkim]

most likely a slight hit in mpg. (5 mpg??)

how much will depend on how much fun you're going to be having twisting the throttle. no kidding... the bike will be a lot more fun now.

[Buffalony]

Originally Posted by kkim

most likely a slight hit in mpg. (5 mpg??)

how much will depend on how much fun you're going to be having twisting the throttle. no kidding... the bike will be a lot more fun now.

With or without an exhaust? You did the mod before the exhaust right kelly? Was it that noticeable?

I'm getting around to this. I just got the 3mm washers and some other stainless parts from desmoparts. good company. I forgot to order the stinkin bolt for the covers though and shipping is $6 argh!

[kkim]

It doesn't really matter. When you shim the needles, you are letting more fuel into the mixture at the carbs, so more will get sucked up at any comparable throttle setting from idle to about midrange. You might see a greater hit with an exhaust due to the freer flowing benefits of a full exhaust system, but the main mpg decrease would be from the needles in the carbs being higher.