Another "sync board" DIY

[Olie]

FedEx delivered my Area P exhaust and dynojet custom kit on Wed. and I've been planning the overhaul for several weeks. I knew the carbs were gonna need to be cleaned so I incorporated the exhaust install with a complete carb tear down, removal of clean air system and CA emissions crap and then a sync of the carbs. I researched a ton on the carb sync DIY and decided to make my own. It's bits and pieces of others that have been posted but I will post up how I made mine in case anyone is interested.
The items used to make my "sync board" tool. The board I found was way too big but being on an island, you take what you can get. There's 20' of 1/4" OD vacuum tubing ($.29 a foot) and I used some Gum Out for the liquid as it's all I had and it wouldn't hurt anything if it got sucked into the carbs. I had some 1/4" coax staples so I used those to attach the hose to the board.
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I simply placed the middle of the 20' section at the bottom middle of the board. The size will be overkill but hey, bigger is better, right? I soon realized the staples wouldn't hold the tubing very well so I wrapped the tubing with some stretch and seal tape. Worked pretty well.
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I then measured 4.5" to each side to begin the run up the board.
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I ran both sides up the edges of the board, attaching them every 12". Again, I'm sure it's overkill but I had plenty of material so why not make it bigger.
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I had already made ports after removing the clean air system so all I had to do was pull the plugs and attach the tubing from the "sync board".
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I then took one end of the tube and put it in the Gum Out bottle and sucked on the other to pull in the desired amount of liquid.
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Getting it to the desired level is no easy task, it takes FOREVER for the fluid to either fill the tubing you want or drain off the extra after you realize you put way too much in. So, once I figured out I would be waiting for the extra to drain off, had a tasty beverage to keep me cool in this lovely Hawaii mid afternoon heat! (I cleaned and lubed my chain too)
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Once it all settled down, I attach the tubing lines to the T's I had installed on the vacuum lines
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Fired her up and the carbs were definitely out of sync
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So a stubby #2 screw driver in the wide open space made by removing the clean air crap
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Sorry for the crappy quality but you see the carbs are now in sync!
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Here's a wide view of the the bike running while attached to the "sync board".
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Finished all of this and put her back together. There was no way I wasn't going to go for a test ride after 2 days of tearing this bike apart. I still have some fine tuning to do but she idles perfectly. Kinda hard to really test drive her on a Saturday night around a military base (cops EVERYWHERE) but she pulled hard throughout, no popping or bogging that I could tell. Only issues I have seen is she was definitely running hotter and when I turned the engine off, I had to twist the throttle to get her to start up. After that the idle was solid and stable. The exhaust sounds amazing!

I big THANK YOU to Kerry from Area P (@kbryant). I emailed him on a Saturday thinking I wouldn't hear back until Monday but instead he replied in less than an hour!
Gave me great advice and my test ride proved it!

[CZroe]

How hard could it be to fill? I wondered the same thing when reading the various versions of this DIY on ninja250.org. Can't you just dip one end into the reservoir and suck on the other end like a straw?

[Olie]

Originally Posted by CZroe

How hard could it be to fill? I wondered the same thing when reading the various versions of this DIY on ninja250.org. Can't you just dip one end into the reservoir and suck on the other end like a straw?

Yes, that is how I filled it. The thicker the fluid and the length of the tubing will determine how difficult it is to fill. The Gum Out I used was fairly thick. Once you have your desired amount in the tubing, there is going to be residual left on the tubing walls so I waited for that to drain out as well. Really, it just gave me a reason to drink and take a break..

[mgentz]

Good stuff!