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Old January 29th, 2016, 07:56 AM   #1
peperino
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2 more q's. Carb removal and clutch switch

Hey guys, it's me again. 2012 250r.

I keep taking the bike apart to make sure everything is fixed, I have 2 q's.

1) How do you take out the right side carb airbox clamp ? (its a 3mm allen bolt). Seems like I get blocked by the frame. How to access it? I'm trying with a T wrench without luck, it won' fit properly

2) My bike won't start in 1st even with the clutch in. I checked the clutch switch and seems to be running fine. I bridged the clutch connector to try to start the bike in 1st but nothing happens. Where to look further?

Thank you!
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Old January 29th, 2016, 08:18 AM   #2
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1. Ball end hex heads help when you can't go straight in. They allow you to access it at a slight angle

2. Is the kickstand up or down?
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Old January 29th, 2016, 08:21 AM   #3
peperino
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Would you mind showing me a picture of the tool you mention?

KS down or up, no difference.
Afaik when you pull the clutch in the bike should start no matter what position the KS is in anyway

Thank you
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Old January 29th, 2016, 08:26 AM   #4
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Quote:
Originally Posted by peperino View Post
Would you mind showing me a picture of the tool you mention?

KS down or up, no difference.
Afaik when you pull the clutch in the bike should start no matter what position the KS is in anyway

Thank you
I belive this is what he is taking about.

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Old January 29th, 2016, 08:28 AM   #5
peperino
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Oh damn
So that ball end will fit the 3mm allen bolt?
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Old January 29th, 2016, 08:33 AM   #6
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Quote:
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Oh damn
So that ball end will fit the 3mm allen bolt?
Yeah, you can get a 3mm allen with a ball end, and the end will fit the hole and help if the allen is angled slightly.
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Old January 29th, 2016, 08:34 AM   #7
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Awesome thanks
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Old January 29th, 2016, 08:34 AM   #8
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Yeah they come in all sizes. I have ones that go on a ratchet so you can get leverage.

Also the bike has a KS safety switch which kills the bike if you put in in gear with the KS down. Start it in neutral and shift into 1st with it down. This would prevent you from starting with the clutch in if it was down normally.

Check the wiring. My switch broke in a lowside.
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Old January 29th, 2016, 08:39 AM   #9
peperino
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Quote:
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Yeah they come in all sizes. I have ones that go on a ratchet so you can get leverage.
Thank you

Quote:
Originally Posted by Floki View Post
Also the bike has a KS safety switch which kills the bike if you put in in gear with the KS down. Start it in neutral and shift into 1st with it down. This would prevent you from starting with the clutch in if it was down normally.
Check the wiring. My switch broke in a lowside.
That is true, but I tried both KS up and down. With the KS up, you should be able to start the bike in 1st gear with the clutch pulled in. That's not happening in my bike.

I will recheck, thank you
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Old January 29th, 2016, 09:07 AM   #10
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Quote:
Originally Posted by peperino View Post
That is true, but I tried both KS up and down. With the KS up, you should be able to start the bike in 1st gear with the clutch pulled in. That's not happening in my bike.
Unless a switch, connector or wiring is faulty.
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Old January 29th, 2016, 10:01 AM   #11
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I will re-test the connector, when I jumped the cable my KS was down so the test was invalid. Will re-test thank you !
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Old January 29th, 2016, 05:37 PM   #12
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Alright, so I managed to get the carbs out. Hard, but doable.

Now, the previous owner installed a #100 main jet. Should I bother trying to get the standard #98 as per the manual or leave it like it is? The bike has the stock muffler. Not sure about the needle, and pilot jet values, I still have to check.

Also, should the jet holder have only 2 holes in it? I was expecting to have many holes in it.

Thank you
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Old January 31st, 2016, 05:15 PM   #13
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Guys, is there a trick to install the air filter side of the carb? I'm struggling to get the boot properly seated on that side, when I tighten the clamps I can clearly see some holes and it is not a smooth fit.

Any trick? I have the air filter box loosen and can wiggle a bit but I can't seem to get a perfect fit
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Old January 31st, 2016, 05:15 PM   #14
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Btw, not sure if that matters but I rotated the clamps so I have the adjusting screw on top instead of bottom. Is that ok ?
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Old January 31st, 2016, 06:49 PM   #15
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When I'm on the 1st gear, engine stops if I kick the KS down (KS wiring simply stops the engine)

But somehow my bike won't start on the 1st gear with clutch pulled (KS up).

I don't mind as long as the bike can start and run as it should.
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