ok. after about 7 hours of install time, (including driving out to get my frickin exhaust gaskets), its all done.
see my thoughts at the end. NO CHEATING! :-D
btw, i gloss over alot that you should be able to follow by reading the maintenance manual. surely you werent thinking about attempting this w/o the manual. because that would be dumb. very dumb. ;-)
critical info:
needle e-clip on 3rd position from top.
no airbox mods. snorkel intact
dj098 main jets used
jetkit first:
remove black plastic piece, and seat
remove front fairings
gastank needs to come off. make sure you either mark or know where all the tubes go
take out the battery and holder. loosen the securing bolts for the airbox
battery out!
the battery holder out too
ok. now there is a big gap: getting the carbs out was a pain in the ass. you need to disconnect some tubes, and loosen the clamps securing the airbox to the carbs, and the clamps securing the carbs to the engine. there wasnt alot of space, and i had to spend about an hour coaxing it out of there. also, you have to disconnect the throttle cables, and the choke cables, which means you have to open up both boxes on the handle bars. again, use the manual.
here it is out. rear side, towards airbox
front side towards engine
unscrew the 4 screws holding down that black cap, and pull it off. you are greeted with this:
take out the spring and the plastic seat thing (white)
here is the order of assembly, w/o the diaphram shown. my 1 washer shim is next to it
here is a close up comparison of the 2 needles. stock right, dj left
needles, with the eclip and their 2 spacers. spacers go ON TOP OF THE E-CLIP. not like the shim where it goes under the head of the needle
here is the needle with the e-clip in 3rd position from top.
stick everything back into the diaphragm
set the spring in the center of the black cap. make sure the diaphram's lip is tucked into the metal correctly. you dont want to pinch the diaphram. just ask spooph.
left side is harder. you have to remove the vacuum slide, and get those 2 tubes out of your way.
now we need to install the main jets, and dril out the fuel/air mixture screw.
this is the carb with the bottom off:
float = white
now this is where things got... interesting. i unscrewed the bottom of the carb sideways, and gas went EVERYWHERE. soaked everything, including my phone that i was using to take pictures. the whole phone was sopping by the time i got to it. display is like an aquarium. keys are all clicky cause the gas reacted with the plastic. all the stickers on the battery got all gummy... im messing with it, but note to all: unscrew the carb bottom with the bottom facing UP!
so here is the main jet. first gold thing below the floats
dj098 on the left, stock jet and tube thing on the right. the tube screws in, then the jet screws into it. dont have to take out the tube, but i did cause im stupid.
hold in the tube with a wrench/spanner or w/e, then unscrew the jet with a flathead.
now time to drill out the fuel/air mixture screws. its covered by that plug that has a bit of sharpie on it
plug sucessfully violated.
stick that screw in there, then use a pair o pliers to pull it out.
now that you can see the screw, screw it back in, and count the number of turns.
my left one was like .75 turns different from my right one. could account for some of the wonkyness i was having
now turn it out slowly 3 full turns. you want both screws to be the same number of revolutions out, but they dont necessarily have to be pointing the same way. mine werent.
now, put back in the carbs, and make sure all the hoses are hooked up. this completes the jetkit installation. next up is the exhaust:
if you get an exhaust, dont skimp. buy the gaskets. also, dont be like me and try to get the gaskets late, cause i ended up having to wait for a long time.
take off the heatshield of the exhaust
loosen exhaust clamp
unbolt the exhaust hangar
slide that mother off!
here are the headers. loosen up the bolts
there is a hidden bolt below the footpegs. dont forget this one.
old grody headers
new hotness
install the copper gaskets onto the new headers, like the one on the right
bolt er in... 9ft lbs of torque? i forget, its not something you need a cheater bar for.
ok that part is done.
i applied the rubber insulator to the exhaust hangar.
slip that hangar onto the exhaust
slide the exhaust onto the header, and bolt it on. the big silver washer from the stock hangar gets moved from the outside to the inside, per yoshimura instructions.
w/o the heatshield
put the hooks on where the header joins the canister. this is about under the foot pegs.
both secured
now put the heatshield on
now you are done. reassemble, and see if the bike works ;-)
i only had 1 leftover piece when i was done! i forgot to put this back on:
it goes on where the tank mounts. im planning on putting it back on tomorrow. it sucks cause i have to take off all the body panels again.. but its ok, at least it wasnt something from the carbs
ill put up b4 and after pix later. gotta clean my bike, and im really tired.
review:
so first starting the bike i thought i f**ked something up. it didnt wanna start, choked out, ran rich, then lean, yadda yadda. i primed the carbs, and that helped a bit, but it just didnt wanna idle nice for me. then i figured out that it was cause i only had a gallon in the tank, and it was on the rear stand. i took it down, bumped the idle a bit, and it runs great.
with the silencer in, it sounds badass. subdued, but still badass. ill try with out the silencer later, and hopefully up a youtube.
the jetkit is amazing. now it really does pull all the way to redline. it has a much smoother power curve. it has power from about 3k, and is basically linear up as far as you want it. it definitely moves alot faster, and is WAY more fun to ride. the 2fiddy review of it is really spot on. go check it out if you need more incentive to get the kit.
seriously. get this.
any questions, or w/e, let me know.
