Rebuilt my carb, now throttle bracket is getting stuck when pulling on throttle

[ZackTheReaper]

Just rebuilt my carbs and reinstalled them. When I pull on the throttle the bracket holding the push and pull cables get caught. I can force it to break through. It does the same when you release the throttle. Any advice?

[ducatiman]

bracket has been broken/incorrectly repaired, should be 1 piece (enlarge photo, see yellow highlight) Get a new bracket, end of issue. .

[DannoXYZ]

Post photo of what you have.

Also make sure you don't have cables crossed or reversed.

[ducatiman]

@DannoXYZ the photo i posted is actually his, i copied it from his post on kawiforums

bracket has been modded or possibly swapped from another model

[DannoXYZ]

The inner wires also look very bent-up and frayed as well.

Here's video of working system:

Link to original page on YouTube.

[ZackTheReaper]

I took the carb out, re cleaned it and check everything over. And out I back in and it stopped getting caught. The bike starts and will idle just under 2k the choke open. If I close it, it goes up to 6k. If I give it any throttle ( choke open or closed) it bogs down and dies. I’m not sure if there is a vacuum leak or didn’t screw a jet in enough or something.

[ducatiman]

all carb internals:
*accounted for? (needle jets have a strange way of going missing)
*reassembled correctly using new orings where called for?

*pilot screws set correctly (2-2.5 turns out) for your application?
*orings present, in correct order?)
*on '09 jet needles are positioned correctly? (they differ L and R)
*jet needles assembled correctly....directly into slides?
*carbs inserted fully (forward) into their manifolds?

All common issues/errors i've seen

[ducatiman]

https://www.kawiforums.com/threads/r...rottle.387232/

starting yet another thread rather than responding/discussing?

[ZackTheReaper]

I was having troubling finding this one again cause the website runs likes crap on the phone. I’m also brand new to all this and have spent over 20 hrs trying to get this thing to run. I’m pretty sure I’m missing the Imulsion tubes. Hopefully putting those in will fix my problem. Is there anything else specifically I should look for other than cleaning the jets (for the 3rd time now). I have new fuel hoses on the way. I couldn’t find any vacuum leaks but that doesn’t mean there isn’t one. I also got a new fuel filter cause the old one is basically toast.

[Triple Jim]

There are some difficult to clean passages that need to be clear.

https://n4mwd.blogspot.com/2013/10/s...-passages.html

[ducatiman]

Originally Posted by ducatiman

all carb internals:
*accounted for? (needle jets have a strange way of going missing)
*reassembled correctly using new orings where called for?

*pilot screws set correctly (2-2.5 turns out) for your application?
*orings present, in correct order?)
*on '09 jet needles are positioned correctly? (they differ L and R)
*jet needles assembled correctly....directly into slides?
*carbs inserted fully (forward) into their manifolds?

All common issues/errors i've seen

in that case, respond to the above allowing us at very least a baseline/beginning

[ZackTheReaper]

I took the carb out again and put in the missing pieces and doubled checked everything. It stared up and worked fine! It’s kinda bogging around 8-10k rpm. I’m gonna put more sea foam in there. The pilot jets hole was stripped so I had to thread repair it to get the new pilot jet in. It screw in tight like the other one. That could be the cause but I’m not sure. I may also need to the sync the carb or something. But I have no idea.

[ducatiman]

Originally Posted by ZackTheReaper

I took the carb out again and put in the missing pieces

WTF?

[ZackTheReaper]

Well thanks someone on the other thread, he said it’s probably my idle screws. I have them at 2 turns right now. I also probably need to sync my carbs. Liek I said before already, I found the Imulsion tubes fell out so put them back in. It idles at 3k plus and bogs/ stutters at 8-10k.

[ducatiman]

"I found the Imulsion tubes fell out"

as they are threaded in.....how could that happen?

IF you are actually referring to needle jets....they are captured underneath the threaded emulsion tubes.

Thus impossible for either to "fall out"....unless you installed needle jets incorrectly.

[ZackTheReaper]

I probably called it the wrong name. It’s the little pins the go under the main jets or whatever. I have taken it out three times now and watched multiple videos on how to put it back together. I have quadruple checked everything before I put it in last. Like I said, the giy in the other forum said, it’s probably my idle jets. I also have a big yoshimura (fake) on there that might also be affecting the idle jets. I’m going to do some tweaking today. My friend who is also a car mechanic has been helping me out this whole time. We the carb has all new jets and needles so nothing should be clogged. We have cleaned the **** out of 3 times now, each cleaning better than the last. My only problem now is high idling and bogging at higher rpms. Can’t get it to red line really. Before I cleaned the carbs the bike would barely start and would only run with the choke closed. And it wouldn’t go over 2k rpms. I probably need to sync the carbs too. If you have any idea as to why it would bog at higher rpms, that would be great.

[Triple Jim]

Originally Posted by ZackTheReaper

We the carb has all new jets and needles so nothing should be clogged.

Are these Keihin jets, in original orifice sizes?

[ZackTheReaper]

I got the Frezon Carb rebuild kit on Amazon

[Triple Jim]

Originally Posted by ZackTheReaper

I got the Frezon Carb rebuild kit on Amazon

Carb kits are notorious for containing incorrect jets. So much so that it's recommended that they never be used for anything other than the gaskets, float needles, and seats. It's likely that if you were to thoroughly clean your originals and put them back in, it would run properly. Verify that they have the Keihin logo on them though, and the sizes are correct, in case a previous owner was messing around.

[ZackTheReaper]

Alright sweet! I’m gonna sync my carbs here soon then mess with my idle screws again. If it’s still bogging I’ll probably swap some of the new needles and jets out for the olds ones. I appreciate the help man! Any info helps. I’m still really new to all this. This forum has been a big help.