How to Repair the Carburetor in a Kawasakiby Kelvin Hayes
Repairing a Kawasaki carburetor is made easy by model-specific "rebuild kits" that replace all the gaskets, jets, floats and O-rings necessary to make the carburetor function like new. Because carburetors are subjected to high heat and are required to ingest air from the exterior of the engine, jets get plugged with debris, float valves wear down and gaskets/O-rings crack. Including disassembly and reassembly, repairing a carburetor will take at least three hours to do and will require the carburetor to be completely detached from the vehicle.
Loosen the air filter boot clamp and the intake manifold screws from the carburetor. Slide the fuel delivery line off its port on the carburetor, ensuring the fuel line is turned off first to avoid spillage. Slide the carburetor out of its position to access the top cap of the carburetor, where the throttle cable is still attached. Use a screwdriver to remove the cap and slide the cable out of its connection point on the needle slide assembly by hand.
Remove the carburetor from the vehicle by loosening the screws on the hose clamp and intake port with a screwdriver.
Set the carburetor on a flat bench inside a shallow pan. Unscrew the bottom bolts that attach the bowl to the rest of the carburetor body with a box or socket wrench.
Remove the bowl, float valve, choke plunger and bowl gasket.
Remove the needle, pilot and main jets. The pilot and man jet will have hex heads that can be removed with pliers or a small wrench. The needle jet attaches to the throttle body and can be removed by disconnecting it from the throttle cable assembly. Remove the springs that operate the throttle body. Pay close attention to how the parts came out for later reassembly.
Ensure that all O-rings are removed from the carburetor body and spray the interior of the body and bowl with a carburetor spray cleaner. Use a soft bristle brush to remove any fuel residue.
Insert the new jets, O-rings, springs and float valve. Attach the bowl gasket and bowl to complete the rebuild.
Reattach the carburetor to the engine and make any idle/throttle adjustments, as necessary, with the idle adjustment screw and the throttle body nut, respectively.