I have a 2004.  I am so frustrated that I might just return to 100% stock and sell the bastard.

I got the idea to try to put in some K&N pods so I ordered those.  Then I got the idea that it will probably need to be rejetted so I ordered the Dynojet kit.  For your information, the DJ kit entails installing their needles, their springs, their "128" mains, their pilots and mixture screw out 3 turns.

I installed the DJ kit and the K&N pods and start the motor and it idles really rough but it does run.  When I blip the throttle the idle revs up to 5000-6000 and only settles down after I either give a little choke or click it into 1st gear and let out some clutch and even when it settles down it is a rough idle.

Dynojet troubleshooting instructions said to put the originals needles back in.  Done.  Same problem.  No difference no matter how much I change the mixture screw either.

Sounds like air is getting in somewhere it shouldn't, right?  I have checked and rechecked all the vacuum hoses.  I have tried spraying WD40 around where the carbs attach to the engine - no good.

Before I go back out their and put everything back to stock (which may not even fix it), do any of you have any ideas or suggestions?

Thank you in advance for your advice.

-Paul

Try the procedure at the bottom of the link page:

http://www.angelfire.com/mt2/mikesgs500/rejetting/

if it doesnt work, I would put the stock air box back in and try it again.


Hope this helps
Chris

Wait...do you have a stock or aftermarket exhaust?

If you have a stock exhaust you should use the 124 jets!  (I'm reading my DJ "stage one instruction sheet")

If you have an aftermarket exhaust you should use the 128 jets.  I have a V&H exhaust with the DJ kit and a K&N pod filter in my airbox and it works great.

Another thing:  when you say "pod" do you mean the k&N stock replacement tube or the "lunchbox" filter that replaces the actual airbox with a K&N filter?  If you mean you installed a lunchbox filter then you will need to play with the mixture screws first and then adjust the idle screw.  The lunchbox lets more air in than the pod filter, so you should need more fuel to compensate NOT less.  Please don't go back to stock yet.  Try to troubleshoot with people who have the lunchbox filter installed (if that is what you have).  Be patient.

-Patrick

w32

Chris:  I did see your page before.  Thanks.  I'll try that.

Patrick:  I have stock exhaust and I am attempting to use two seperate K&N air filter pods (one for each carb) that replace the stock airbox altogether.

Wrecent:  I have triple check the seals around the float bowls and the diaphragms over the black, plastic pistons.  I replaced the mains according to the K&N diagram (http://www.dynojet.com/pdf/3156.pdf).  In my 2004, the mains are the tallest.  Have not checked float height.  Only things I had to drill out were the mix screw plugs.


So, I will try Chris's method of mix screw setting and then try the stock airbox again.

Aany other suggestions??

Man...another person with this hanging throttle symptom.... trying to figure mine out on my 96.

    "Chris:  I did see your page before.  Thanks.  I'll try that."


Just for the record, not my page.

But it was very helpful for me me I rebuilt my carbs.


Chris

So if you have the stock exhaust shouldn't you be using the other main jet? I just did  a rejet without the filter (waiting for it to come in) and the bike runs mint.  So other then the jet's my bike is stock. Problem with a carb you could have the slightest thing go wrong and never know about it.

I don't think stock exhaust go well with pod filters. Not that i suggest to go buy one, but take it into consideration.

Quote from: domas on May 23, 2006, 11:51:06 PM
I don't think stock exhaust go well with pod filters. Not that i suggest to go buy one, but take it into consideration.

I've got a lunchbox (similar to pods) with stock exhaust. Works fine.

We should all get off the coumputers right now and go riding. 

I'm up for it...

Quote from: dwn4whadever on May 24, 2006, 12:07:49 AM
We should all get off the coumputers right now and go riding. 

I wish. Too damn tired to ride, but not tired enough to sleep. Plus, if I take any decent length of a ride I'll hit 12k miles and need to do a valve check. Maybe Thursday.

you check valves ever 4000 miles.

Quote from: dwn4whadever on May 24, 2006, 12:34:35 AM
you check valves ever 4000 miles.

Yup. I do the full maintenance schedule on my own. Not worth it to take it into a shop when I can check them in half an hour in my driveway.

I have a question : when installing pod or lunchbox filters people put a breather filter on crankcase breather hose. BUT it should be connected to an airbox and as i understand it there is negative pressure in stock air box, which is sucking bad fumes out of crankcase. Fitting the hose with a separate filter or letting it just hang, leaves the crankcase without negative pressure and the bad fumes dont come out so well anymore.

Is this a problem (or possible could be)?

3d

Quote from: dwn4whadever on May 24, 2006, 12:07:49 AM
We should all get off the coumputers right now and go riding. 

Couldn't agree more!!  I just have to get the bastard running right first.

 

So now I have taken off the K&N pod style filters and reinstalled the OE airbox.  I still have the Dynojet kit installed per its instructions (see settings in my previous posts within this thread).

It runs better than it did with the pods but still not as good as it did before I started all of this.  It idles rough and, while idling, it sometimes runs up to between 3000 and 6000 RPM, hangs there for a bit, then comes down.  I am using no choke.  Still seems like a vacuum leak to me but I have checked all the usual suspects.

My next step is to keep playing with the air mixture screw and, if that does no good, I'll put the stock needles back in.  If THAT doesn't work, I'll go back to 100% stock with all the stock jets.  If it IS a vacuum leak that I've created none of this will fix my problem, not even going back to stock.

I wish I had never started this.  If it keeps up, I'll be posting a "F/S" in the classifieds.

Any further suggestions/tips/ideas/etc.

nobody?  I guess I have to take it to a mechanic.