#3238 EXCITER b/C 44mm MIKUNI CARB KIT INSTRUCTIONS
1. Remove secondary clutch, this will make installation much easier. Remove carb slides by unscrewing tops of carbs. Loosen front and rear carb clamps, remove choke cable ends from carbs, remove air box mounting bolts. Two of the air box mounting bolts are under a small panel on the left side of the dash.
2. Disconnect T.O.R.S. switch wires at carbs. Reconnect the harness ends together. This will override your T.O.R.S system. Note: We recommend that you purchase and install a tether cord safety switch on your sled for your safety in the event of a throttle sticking!
3. Disconnect the fuel lines and remove carbs & airbox from sled.
4. Remove old fuel line to fuel pump and install new fuel line. Install new carb intake manifolds. Note: Be sure to center the manifolds with the intake ports before tightening.
6. Hook up new choke plungers and adjusters to choke cable ends. Install them into carbs and tighten them, set adjusters so when choke is off there is 1/8" of freeplay in cables.
7. Tighten carb clamps with carbs in vertical position.
8. Tie strap ignition coil and CDI box to the upper radiator hose using supplied tie straps, make sure ground wire is bolted to ignition coil using supplied bolt.
9. Start engine and warm up thoroughly. Now disconnect one spark plug wire and install a spare plug. Lay plug on a metal surface to ground out. Start engine and run on 1 cylinder. Leave off throttle and adjust idle speed on running carburetor to 900 RPM. Now switch plugs and adjust the other cylinder to run at 900 RPM. Now reinstall both plug wires and start engine again. Idle speed should be approximately 1500 RPM with both cylinders operating -if it’s not equally adjust both idle speed screws in or out to obtain proper idle speed. Now with engine still running, slowly unscrew the cable slack adjusters on one carb (there are two cable slack adjusters, one on top of the carbs, and one on the cable 90 degrees elbow), until the RPM just starts to increase, in other words until all the slack has just been removed. Do this for both cylinders. Shut off engine and turn in each adjuster exactly one turn. Tighten the lock nuts and your carburetors are now synchronized.
10. Now adjust oil pump cable so that when throttle is held wide open you can see the dimple in the cable slack adjuster when all the free play is pulled out of the cable at the adjuster.
11, Double check all work done including fuel leaks, cable routing, and manifold screws.
12. The two vent hoses on the sides of the carbs should be left hanging down on each side of the carbs.
NOTE: Carbs have been prejetted with #320 mains and #115 power jets for 0—3000 feet elevation with our #3237 twin pipes & #3236 hot trail porting with supplied K&N air filters installed. The standard air screw setting is 3/4 turn out but can be changed depending on weather. Jetting is safe down to -1OF degrees. Any other modifications or elevation would necessitate a jetting change.
CAUTION: To avoid engine damage absolutely no internal engine or carb modifications are encouraged other than what is recommended by Reichard’s Performance Center.