Tuning Instructions for Harley

Tuning Instructions for Harley
TUNING INSTRUCTIONS
For Harley-Davidson Carburetors
©2003 Edelbrock Corporation
Brochure No. 63-0195
Rev. 8/03
INSTALLATION PROCEDURE
Please study these instructions carefully before installing your new Edelbrock carburetor. This tuning manual is for HarleyDavidson only! If you have any questions or problems, please call our Technical Hotline at: 1-877-888-7504 ext. 2,
8:00 am to 5:00 pm, Monday - Friday, Pacific Standard Time or e-mail us at edelbrock.edelbrock.com.
The Edelbrock Performer Series Carburetor has five (5)
adjustments:
1. IDLE SPEED: Mechanical, raises and lowers
slide to preferred idle RPM.
2. IDLE MIXTURE (900-1200rpm): Controlled by
air bleed.
3. MID RANGE (1300-3500rpm): Controlled by
needle setting/size.
4. FULL RANGE (3600-6000rpm): Controlled by
main jet.
5. ACCELERATOR PUMP (Off Idle Throttle
Response): Controlled by bypass screw on float
bowl.
THROTTLE CABLE REQUIREMENTS
NOTE: Edelbrock Performer Series carburetors require
the use of a two-cable (push-pull) throttle assembly and
cables. Quick Kits and Complete Kits include throttle
cable adaptors for use with OE CV throttle cables. For
early EVO Big Twin (84-89) and EVO Sportster (86-87) ,OE
cables can be used without any adaptors. Shovel Head
and Iron Sportster will require use of Edelbrock throttle
cables. Models not equipped with a dual cable throttle
assembly will require one. Edelbrock offers an
economical dual cable throttle assembly part #8273.
Edelbrock cables can be used in place of OE cables on all
EVO and Twin Cam applications.
*84-95 Black
*84-95 Stainless
96-up Black
96-up Stainless
35”
8268
8269
8680
8681
40"
8276
8277
8682
8683
45"
8271
8272
8684
8685
50"
8607
8608
8686
8687
CARBURETOR REMOVAL
Edelbrock recommends consulting an authorized service
manual for make, model and year of motorcycle before
disassembly of stock parts.
1. Turn fuel valve off before getting started.
2. Disconnect battery to eliminate the possibility of
sparks or accidentally engaging the starter.
3. Remove air cleaner assembly.
4. Disconnect choke cable from its bracket.
5. Disconnect fuel line and vacuum lines from
carburetor.
6. Gently remove carburetor from manifold.
NOTE: For removal of CV style carbs, Edelbrock
recommends the carb be gently wiggled from side to side
(not up and down) while pulling to get carb out of
manifold.
MANIFOLD REQUIREMENTS
Edelbrock Quick Kits and Complete kits are designed to
work with the stock manifold that was OE on your engine.
Some aftermarket manifolds will also work with
Edelbrock carburetors. S&S "E" Series and Screamin’
Eagle flange mount manifolds will work with Edelbrock
flange style carburetors. It is also recommended the
manifold being used closely matches the venturi of the
carburetor.
BIKE PREPARATION
Dual cable throttle assembly 8273.
*These cables may also use Edelbrock dual cable throttle
assembly part no. 8273.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 1 of 16
1. Once stock carburetor and air cleaner have been
removed, inspect manifold grommet (CV
manifolds only) for tears, nicks or cuts. Replace
grommet, if damaged. Stuff a clean dry rag into
manifold until carb is installed to keep any debris
out of engine.
2. Remove old fuel line and vacuum line (if
equipped) and install supplied fuel line and
vacuum line.
Rev. 8/03
3. If replacing throttle cables do so now. Pay close
attention to cable routing when removing old
cables as you will need to route the new cables in
the same location.
NOTE: If re-using existing cables, bottom
adjusters by loosening locknuts and thread
adjusting screw so there are no threads showing.
Inspect inner cable for kinks or fraying. If cable
is in bad condition, it can stick causing loss
of control of the motorcycle resulting in
injury to you or others. It is recommended
damaged or worn cables be replaced.
Fig. 2
5. Route enrichener cable over manifold and secure
into cable bracket on left side of engine.
6. Mount carburetor to manifold using supplied flange
gasket. NOTE: Before installing carb into CV
manifold, lubricate the grommet with a light film of
grease or liquid soap.
7. Once carb is secured to manifold, adjust throttle
cables by extending adjuster on pull cable until full
throttle is achieved at carburetor (slide completely
disappears out of venturi). Take up slack in throttle
grip by extending adjuster on push cable until there
is approx. 1/8" of free play at grip. NOTE: If cables
are adjusted too tight, it could cause cables to bind
or stick.
8. After cables have been adjusted, rotate handle
bars from full right to left several times to ensure
cables do not bind or get caught on any
obstructions.
CARBURETOR INSTALLATION
Edelbrock carburetors come out of the box ready to be
installed onto the engine.
1. Remove right side cable bracket end and install
throttle cables into cable wheel with the "pull"
cable locating in the 8:00 position of the cable
wheel and the "push" cable locating in the 11:00
position of the cable wheel. See Fig. 1.
Fig. 1
AIR CLEANER INSTALLATION
NOTE: If using CV throttle cables, the use of the
supplied throttle cable adaptors will be required.
Install the adaptor with the longer small end onto
the "pull" cable. Install the remaining adaptor
onto the "push" cable. NOTE: Removal of the
small spring on the push cable can be removed if
additional free play is needed.
2. Secure cables to cable bracket by replacing cable
bracket end and tightening phillips screw.
3. Install fuel line and secure with supplied hose
clamp.
4. Install vacuum line onto vacuum port on back of
carburetor if engine is equipped with VOES. See
Fig. 2.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Edelbrock Performer Series carburetors are designed to
work with either an Edelbrock air cleaner (supplied in
Complete Kits) or any other air cleaner designed to work
with the CV carburetor.
Edelbrock Performer Series carburetor complete kits
include an air cleaner that requires the use of any EVO
Sportster, EVO Big Twin or Twin-Cam air cleaner cover
that fits the factory air cleaner.
If re-using an existing CV style air cleaner, re-assemble
onto Edelbrock carburetor in reverse order of disassembly from CV carburetor.
If installing Edelbrock air cleaner, see section pertaining
to your motor.
Page 2 of 16
Rev. 8/03
1993-LATER EVO BIG TWIN, 1991-LATER EVO
SPORTSTER,TWIN-CAM ENGINES:
9. Connect 3/8" breather hose supplied in hardware
kit onto the barb of the front hanger bracket. Cut
the hose so it will fit onto the "T" fitting without
any kinks. Connect the remaining piece of hose to
the barb of the rear hanger bracket and trim the
opposite to fit onto the "T" fitting. See Fig. 4.
1. Attach chrome hanger brackets to heads using
hollow breather bolts and black fiber washers
with one washer on each side of hanger bracket.
Do not tighten bolts yet.
2. Thread plastic "T" fitting into backing plate until
snug with the "T" sitting vertical. See Fig. 3.
Fig. 4
10. Install filter and sub cover onto backing plate and
secure with ¼-20X1" screws supplied with air
cleaner assembly.
11. Attach stock (OEM) EVO Sportster, EVO Big Twin or
Twin-Cam air cleaner cover with stock screws.
NOTE: It is recommended Loctite 242 (blue) or
equivalent be used on cover screws.
Fig. 3
3. Attach backing plate and gasket to carburetor
using three (3) ¼-20X1/2" button head screws.
NOTE: It is recommended that Loctite 242 (blue)
or equivalent be used on all three screws before
installing.
4. Line up ¼" holes on each side of backing plate
with the slotted ¼" holes in each hanger bracket
attached to heads in step 1.
5. Determine spacing between hanger brackets and
backing plate and which spacer or combination of
spacers will best fill in the gap.
NOTE: Make sure the carb is securely attached to the
manifold before checking the spacing. If more
spacers are used than required, it can pull the
carb out of a CV manifold causing an air leak.
6. Attach the hanger brackets to the backing plate
using either the ¼-20X1" or the ¼-20X11/2"
button head screws by going through the backing
plate and spacers then through the hanger
brackets. Place 1/4X1/2" washer then ¼" Nylock
on end of screw to secure backing plate and
spacers to hanger brackets.
7. Align carb as vertical as possible and tighten the
Nylock nuts on each hanger bracket.
8. Tighten breather bolts in heads. Do not over
tighten as bolts are hollow and can break much
easier than a standard bolt.
©2003 Edelbrock Corporation
Brochure No. 63-0195
1984-1992 EVO BIG TWIN, 1986-1990 SPORTSTER
Page 3 of 16
1. Attach chrome hanger brackets to heads using the
two 5/16-18X11/2" chrome button head bolts and
chrome reducer sleeves. Do not tighten bolts
yet.
2. Thread plastic elbow into backing plate until snug
with the barb facing down.
3. Attach backing plate and gasket to carburetor
using three (3) ¼-20X1/2" button head screws.
NOTE: It is recommended that Loctite 242 (blue)
or equivalent be used on all three screws before
installing.
4. Line up ¼" holes on each side of backing plate
with the slotted ¼" holes in each hanger bracket
attached to heads in step 1.
5. Determine spacing between hanger brackets and
backing plate and which spacer or combination of
spacers will best fill in the gap. NOTE: Make sure
the carb is securely attached to the manifold
before checking the spacing. If more spacers are
used than required, it can pull on the carb and
manifold resulting in an air leak or broken
manifold.
Rev. 8/03
6. Attach the hanger brackets to the backing plate
using either the ¼-20X1" or the ¼-20X11/2"
button head screws by going through the backing
plate and spacers then through the hanger
brackets. Place 1/4X1/2" washer then ¼" Nylock
on end of screw to secure backing plate and
spacers to hanger brackets.
7. Align carb as vertical as possible and tighten the
Nylock nuts on each hanger bracket.
8. Tighten hanger bracket bolts in heads.
9. Connect 3/8" breather hose supplied in hardware
kit onto the barb of the elbow with the other end
connecting to the crank case breather.
10. Install filter and sub cover onto backing plate and
secure with ¼-20X1" screws supplied with air
cleaner assembly.
11. Attach stock (OEM) EVO Sportster or EVO Big Twin
air cleaner cover with stock screws. NOTE: It is
recommended Loctite 242 (blue) or equivalent be
used on cover screws.
1957-1985 IRON SPORTSTER
1966-1984 SHOVEL HEAD
1. Loosen top center case bolt and remove nut from
right side.
2. Remove bottom flange bolt holding carb to
manifold.
3. Install flat steel air cleaner support strap on the
case bolt and replace manifold bolt through the
top hole of the strap.
4. Replace nut on case bolt and torque to proper
specs. Tighten manifold to carb bolts at this time.
5. If connecting case breather to air cleaner, thread
elbow into backing plate until snug with elbow
pointed down.
6. Attach backing plate and gasket to carburetor
using three (3) ¼-20X1/2" button head screws.
NOTE: It is recommended that Loctite 242 (blue)
or equivalent be used on all three screws before
installing.
7. Install filter and sub cover onto backing plate and
secure with ¼-20 x 1" screws supplied with air
cleaner assembly.
8. Attach stock (OEM) EVO Sportster or EVO Big Twin
air cleaner cover with stock screws. NOTE: It is
recommended Loctite 242 (blue) or equivalent be
used on cover screws.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 4 of 16
1. Remove outside rear bolt from the front cylinder
lifter block.
2. Install threaded stud into vacant hole where bolt
was removed from lifter block with the ½-20
threads up.
3. Remove rubber plug from bottom center of
backing plate.
4. If connecting case breather to air cleaner, thread
elbow into backing plate until snug with elbow
pointed down.
5. Attach backing plate and gasket to carburetor
using three (3) ¼-20 x 1/2" button head screws.
NOTE: It is recommended that Loctite 242 (blue)
or equivalent be used on all three screws before
installing.
6. Install steel air cleaner support bracket with bends
over threaded stud with the long end up and
secure with washer and ¼-20 Nylock nut. Do not
completely tighten yet.
7. Line up hole in backing plate that plug was
removed from in step 3 with the slotted hole in
support strap and secure with ¼-20X3/4 button
head screw, washers and Nylock nut.
8. Tighten Nylock nut holding strap to lifter block
stud.
9. Install filter and sub cover onto backing plate and
secure with ¼-20X1" screws supplied with air
cleaner assembly.
10. Attach stock (OEM) EVO Sportster or EVO Big Twin
air cleaner cover with stock screws. NOTE: It is
recommended Loctite 242 (blue) or equivalent be
used on cover screws.
Rev. 8/03
BACKING PLATE MODIFICATION FOR CV STYLE AIR
CLEANER TO BE USED WITH EDELBROCK/EPS
CARBURETORS
3. Using a round file, file the backing plate until no
part of the backing plate is covering the air bleed.
(See Fig. 7).
All new Edelbrock/EPS carburetors accept either
Edelbrock or any CV style air cleaner.
Since the Edelbrock/EPS carburetor uses an air bleed jet,
a slight modification will need to be made to the CV
backing plate.
1. Using the supplied A/C gasket as a template, line
the gasket up with the screw holes on the air
cleaner flange side of the carburetor.
(See Fig. 5).
Fig. 7
NOTE: Make sure to only remove enough material
fromthe backing plate so the air bleed screw has
no obstructions. (See Figure 8).
Fig. 5
2. Make a mark on the backing plate for the location
to be filled. (See Figure 6).
Fig. 8
NOTE: OEM CV backing plates will not work
with the Edelbrock Carburetor.
Fig. 6
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 5 of 16
Rev. 8/03
CARBURETOR OPERATION
The Edelbrock Performer Series carb is equipped with an
enrichener system for cold starts. The enrichener should
be used for “starting” only when motor is cold. On some
occasions, a cold motor may fire without the use of the
enrichener. The enrichener will not be needed in most
cases as the accelerator pump can be used to prime the
engine by simply twisting the throttle two times before
attempting to start engine.
1. Pull enrichener cable out.
2. Engage starter until motor fires. NOTE: It may be
necessary to crack the throttle open approx 1/8 of
an inch to help the motor turn over faster and aid
in starting.
3. After engine fires, it may require the throttle be
held at a high idle (1000-1200 RPM) for several
seconds to warm engine. NOTE: If enrichener
was used to start engine, idle will become rough
when engine no longer requires the use of the
enrichener circuit.
If a cold motor does not want to start, see
Troubleshooting section at end of this manual.
HOT STARTS
Now that the engine has been run and is warm, the
enrichener will not be necessary.
NOTE: DO NOT OPEN THE THROTTLE ON A PUMPER
SERIES CARBURETOR IF THE ENGINE IS WARM AND
NOT RUNNING! DOING THIS WILL FLOOD THE ENGINE,
MAKING IT DIFFICULT TO RESTART.
The idle speed screw is installed on the carburetor and
pre-set at the factory.
1. Start engine and warm for 3-5 minutes.
2. Once engine is warm, set idle to manufacturer’s
recommended specifications.
NOTE: Idle speed may change when adjustments are
made to the air jet or needle adjuster. This will require the
repeat of steps (1) and (2).
All Edelbrock Performer Series carburetors come preset
from the factory for use on stock based motorcycles with
an aftermarket exhaust. Depending on the modifications
that have been made to your engine, a slight adjustment
to the air/fuel mixture may be necessary.
Before attempting to tune your Edelbrock Performer
Series carburetor, new spark plugs are recommended.
This will make it a lot easier to tune.
Idle Mixture Adjustment
The idle mixture is controlled by the size of the air bleed
located in the mouth of the carburetor. All Edelbrock
Performer Series carburetors are manufactured using a
.035 (red) air bleed. Each carburetor is shipped with two
additional air bleeds for fine-tuning, a .030 (gold) and a
.040 (blue). A larger number air bleed will lean the idle
mixture while a smaller # air bleed will richen the idle
mixture. See Fig. 9 for air bleed location.
If you think the engine is flooded, you can clear out the
cylinders by SLOWLY opening the throttle to wide open
and engage starter for 3-4 seconds. Once this is done,
the engine should fire normally.
If hot start problems persist, please refer to the
Troubleshooting guide at the end of this manual.
ADJUSTING CARBURETOR
Idle Speed Adjustment
The idle adjustment screw mechanically adjusts the idle
by keeping the slide slightly open at idle. This will be
affected by adjustments made to the air jet or needle
adjuster upon tuning the low to mid-range.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Fig. 9
Before making a change to the idle mixture make sure
engine is warm and enrichener is in the “OFF” position.
Determine if the engine needs more or less fuel by the
way the idles:
Page 6 of 16
Rev. 8/03
Lean Condition
These problems can be remedied by richening the needle
position. Turning the metering adjustment tool to the
right does this. It is recommended that adjustments be
made two clicks at a time. NOTE: Before making
adjustments for this condition, check for intake and
exhaust leaks. These leaks have similar symptoms
.
Rich Condition
a. Engine won't idle without enrichener on.
b. Popping or spitting through carburetor.
c. Erratic idle (varies in rpm).
Install smaller air bleed to richen mixture.
Rich Condition
a.
b.
c.
d.
a. Black smoke, strong exhaust odor.
b. Rough idling.
Install larger air bleed to lean mixture.
To change idle air/fuel mixture, use a small flat blade
screwdriver to remove air bleed from carburetor.
Install desired air bleed with a drop of Loctite 242 or
equivalent. DO NOT OVERTIGHTEN AIR BLEEDS
INTO BODY AS THEY ARE ALUMINUM AND MAY
STRIP EASILY!
Air Bleed Color
Size
Part No.
Purple
Black
Gold
Red
Blue
Green
Orange
.020
.025
.030
.035
.040
.045
.050
8170
8171
8172
8173
8174
8175
8176
These problems can be remedied by leaning the needle
position. Turning the metering adjustment tool to the left
does this. It is recommended adjustments be made two
clicks at a time.
NOTE: Before making adjustments for this condition
make sure enrichener is completely off (9:00 o’clock
position).
OFF-IDLE TO MID-RANGE AIR/FUEL MIXTURE
ADJUSTMENT
INITIAL RIDE
NOTE: The engine's street performance is usually the
best way to tune the carburetor. Due to different grades
of gasoline, gasoline additives, altitudes and riding styles
plug readings may differ from engine to engine.
After bike has warmed up and idle speed has been set, it
is now time for an initial test ride. While riding the
motorcycle pay close attention to the off idle to 1/3
throttle position. In this range, watch and listen for the
following:
Off idle to mid-range mixture adjustments are made by
raising or lowering the needle height in the slide. The
needle adjuster is located in the slide on top of the needle
and adjusts the needle height. By turning the center slot
on the needle adjuster to the right (clock wise) will richen
the mixture, or turning it to the left (counter clock wise)
will lean the mixture. These adjustments are referred to
as "clicks". Each click equals ¼ of a turn. The usable
range is approximately 32 clicks with zero (0) clicks being
full rich and thirty two (32) being full lean. The number of
clicks is always referred from full rich.
Example: 14 clicks would be 14 clicks from full rich,
zero (0) clicks. Edelbrock recommends making 1 or 2
click increments when adjusting needle height.
Lean Condition
a. Flat spot off idle
b. Lag in acceleration
c. Popping or backfiring through exhaust or intake
on deceleration.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Lazy acceleration
Poor mileage
Surge at low speeds
Poor fuel economy
Page 7 of 16
1. With engine off, open throttle to wide open.
Remember to open throttle slowly to avoid
flooding.
Rev. 8/03
2. Push red knob down (with throttle still open) and
turn until it engages with the needle adjuster and
some resistance is felt. See Fig. 10. Once
resistance is felt, it is now time to make your
adjustment.
engine modifications. Usually tuning will consist of jet
changes and/or needle height adjustments.
If you feel a needle change is in order, please follow the
following instructions for changing the needle.
See back of manual for available needle sizes and part
numbers.
Fig. 10
Ride motorcycle and pay close attention to the engine's
performance from 1/3 to 2/3 throttle. In this range, watch
for the following.
Lean Condition
a. Will not rev out in higher rpm's.
b. Poor acceleration when throttle is rolled on at
higher rpm's.
c. Detonation (pinging).
Make your adjustments according to the following:
TO MAKE RICHER (MORE FUEL) 0-1/3 THROTTLE.
Rich Condition
1. Pushing down, turn the red adjuster knob to the
RIGHT (clockwise) one (1) or two (2) clicks
depending on the severity of the lean condition.
a. Black smoke from exhaust at high rpm's.
b. Lazy acceleration.
c. Power falls off then accelerates when throttle is
rolled closed slightly.
d. Poor fuel economy
TO MAKE LEANER (LESS FUEL) 0-1/3 THROTTLE.
1. Pushing down, turn the red adjuster knob to the
LEFT (counter-clockwise) one (1) or two (2) clicks
depending on the severity of the rich condition.
2. Release knob and throttle. Restart engine and
reset idle speed if necessary.
Evaluate
performance and repeat if necessary.
NOTE: If proper adjustment cannot be obtained
through the standard range of adjustment see
"Needle size adjustments" later in this manual.
NEEDLE SIZE ADJUSTMENTS
MIXTURE ADJUSTMENT (1/3 -2/3 THROTTLE)
The needle size in the carburetor controls the 1/3-2/3
throttle mixture. Edelbrock Performer Series carburetors
are set up with jetting specs we have found to work on
wide variety of engine combinations. Some engine
combinations may require different air bleeds, main jets
and needle settings depending on the altitude and
modifications done to your engine. 38 and 40 mm carbs
are shipped with a 13-0 needle while 42mm carbs have
a 14-0 needle in them from the factory. We have found
the factory-installed needles to work with many different
©2003 Edelbrock Corporation
Brochure No. 63-0195
NOTE: The main jet also has some effect in this range.
We recommend changing the main jet to see if proper
jetting can be achieved. See Main Adjustments
section.
ADJUSTMENTS-SLIDE REMOVAL
1. Remove air cleaner assembly and carburetor.
2. Turn idle speed screw out until it no longer touches
the carburetor cap.
3. Remove three 9/64-cap screws using Allen wrench
(provided).
4. Lift cap off of carburetor body and pull back
towards air boot /air filter. See Fig. 11.
Page 8 of 16
Fig. 11
Rev. 8/03
5. After cap has been removed, remove the torx
head T-10 screw (See Fig. 12) attaching the
slide actuator strip to the inside wheel.
Fig. 12
6. Remove slide assembly from carb body
7. Turn center slot of the needle adjuster to the right
and count the number of clicks until it stops. This
will allow you to reposition the new needle in the
same location for idle-mid range adjustment. It is
recommended this number be written down for
later use.
8. Line up slots (inner and outer) on the needle
adjuster. See Fig. 13.
Fig. 13
9. Using a wide, flat blade screwdriver remove the
needle adjuster assembly, needle and needle
spring from the slide.
Make needle change according to the following:
b. To make LEANER (less fuel) 1/3-2/3 throttle
position - Read the number printed on the
needle that was just removed form the
carburetor. To make leaner, you will need to
install the NEXT LOWER # needle.
10. Place needle spring on needle with the small end
towards the needle head (up). Insert needle and
spring into the slide, aligning the nub on the needle
head into the groove in
the slide. Insert needle
adjuster actuator pin
into
slide
with
threaded hole up and
also aligning roll pin
into the groove in the
slide. See Fig. 14 for
correct sequence.
11. Put a drop of BLUE
Loctite 242 or equivalent on the upper
threads (above crossdrilled holes) of the
needle adjuster and
install into slide.
Tighten needle adjuster assembly in
slide with a wide, flat
blade screwdriver.
NOTE: Make sure Loctite
does not get into the
crossdrilled holes of
Fig. 14
needle adjuster. If this
happens clean needle
adjuster with WD-40 or a penetrating oil. DO NOT USE
ANY HARSH CHEMICALS TO CLEAN NEEDLE
ADJUSTER ASSEMBLY!
a. To make RICHER (more fuel) 1/3-2/3 throttle
position - Read the number printed on the
needle that was just removed from the
carburetor. To make richer, you will need to
install the NEXT HIGHER # needle.
W A R N I N G ! ! !
Gasoline is very flammable. DO NOT work on any carburetor while smoking or around an open flame. It is
also strongly recommended that any procedure pertaining to gasoline be performed in a well-ventilated
area, as the vapors can be harmful.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 9 of 16
Rev. 8/03
12. Using a 3/16 flat blade screwdriver, turn center
slot of needle adjuster (See Fig. 15) to the right
(clockwise) until it stops. Now turn to the left
(counter-clockwise) counting clicks (one click
equals ¼ turn) until the number acquired from
step 6 is obtained.
Fig. 15
Some adjustment may be needed to this setting
after engine has been test ridden again.
Generally, If you go to a richer needle (higher #)
you will be a couple of clicks leaner on your
setting. Just opposite for a leaner needle (lower
#) richer setting.
13. Install slide into carburetor body and make sure
slide moves freely and will completely close with
it's own weight. Use a drop of BLUE Loctite 242
or equivalent (medium strength) on the 4-40 torx
screw and attach the slide actuator strip to the
inner wheel. When tightening screw, place a
small flat blade screwdriver between the slide
strip and carburetor body. See Fig. 16. This will
prevent the slide strip from twisting.
15. Reinstall carburetor and air cleaner onto engine.
Don't forget to turn fuel on before starting engine.
MAIN JET ADJUSTMENTS
The main jet controls fuel flow from about 2/3 throttle to
wide open. If you have a problem in this area of throttle
opening a main jet change is in order. The main jet is
located in the bottom of the pick up tube and can be
accessed by removing the plug in the bottom of the float
bowl.
1. Turn fuel petcock to off position.
2. Remove aluminum plug from bottom of float bowl
using 11/16 socket or wrench. Use a small cup to
drain fuel from bowl into while removing plug.
WARNING!! Gasoline and gasoline fumes are
extremely flammable. It is strongly recommended when working with gasoline, it be
done in a well-ventilated area away from any
open flames or ignition source.
3. Using a stubby flat-blade screwdriver remove main
jet from pick up tube. See Fig. 17.
Fig. 17
Fig. 16
14. Replace cap and cap gasket onto top of
carburetor body and secure with the three Allen
cap screws. NOTE: Before tightening screws,
open carburetor to wide open and hold while
tightening screws. This will ensure cap is
centered on carburetor body.
©2003 Edelbrock Corporation
Brochure No. 63-0195
NOTE: All Edelbrock Performer Series carburetors
are assembled with a .076 main jet. A .074 and
.078 main jet are included in hardware kit for fine
tuning your engine. Additional jets are available in
.002" increments.
4. Install desired jet into pick up tube. Do not over
tighten jet as brass is soft and can easily strip.
5. Replace bowl plug with o-ring. Do not over tighten
plug when re-installing as it is hollow and can
easily crack or break.
Page 10 of 16
Rev. 8/03
MAIN JET SIZES AND PART NUMBERS
Jet Size
Part #
Jet Size
.062
#8140
.074
.064
#8141
.076
.066
#8142
.078
.068
#8143
.080
.070
#8144
.082
.072
#8145
.084
Part #
#8146
#8147
#8148
#8149
#8150
#8151
ACCELERATOR PUMP ADJUSTMENTS
Edelbrock Performer Series carburetors are equipped
with an accelerator pump; the following will help you
adjust your accelerator pump to its proper settings.
= too much pump shot. Turn adjustment screw
out (counter clockwise) until engine accelerates
smooth.
Do not try to adjust pump by free revving the motor in
neutral. This adjustment should be done then tested
with a load on the motor i.e. riding the bike and going
through the first three gears.
To make adjustments to the accelerator pump, you will
need the following tools: 5/16 or 8mm open end
wrench and a flat-blade screwdriver.
To make adjustment to pump use the following
procedure. See Fig. 18.
The accelerator pump on this carburetor was designed to
only "squirt" fuel during rapid (fast) throttle opening when
the engine requires extra fuel to keep from going lean.
The pump will not squirt fuel during slow throttle opening
as the main fuel system can supply the required fuel for
the engine to perform properly.
Accelerator pumps are primarily used on four-stroke
applications where instant low-rpm throttle response is
desired and/or required. The Edelbrock Performer Series
accelerator pump is easily adjustable to fine-tune the
throttle response and ride ability of the engine to different
combinations and riding styles.
The pump adjustment screw is pre set at the factory to
1.5 turns out.
To make adjustments to the pump, it is recommended you
determine if the engine requires more or less "pump
shot". To determine which way to adjust the pump, use
the following to help guide you.
EXAMPLES:
a.. The engine wants to stall or stumble during quick
throttle openings = not enough pump shot. Turn
adjustment screw in (clockwise) until hesitation
goes away.
b. The engine is sluggish during a "roll on" of the
throttle then cleans out and accelerates normally
Fig. 18
1. While holding the screw from turning, loosen the
jam nut approx. 1 turn.
2. Turn the screw in the direction required for proper
adjustment. Remember: right for more fuel, left for
less fuel. Edelbrock recommends that 1/8 of a turn
adjustments be made until proper pump shot is
achieved.
3. Once pump has been set to optimized setting, hold
screw from turning and tighten jam nut.
GENERAL INFORMATION
FLOAT ADJUSTMENT
1. Turn fuel petcock OFF, disconnect throttle cables
and fuel line from carburetor and remove from
engine.
2. Remove four (4) float bowl screws using the 9/64
Allen wrench provided.
W A R N I N G ! ! !
Gasoline is very flammable. DO NOT work on any carburetor while smoking or around an open flame. It is
also strongly recommended that any procedure pertaining to gasoline be performed in a well-ventilated
area, as the vapors can be harmful.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 11 of 16
Rev. 8/03
3. Drain fuel from bowl into a fuel safe container.
CAUTION!!!
Edelbrock Performer Series
carburetors contain a small brass check needle
that can fall out when bowl is turned upside
down. It is recommended that the bowl be
emptied through a strainer or rag to catch the
check needle. Reinstall check needle (point
down) into hole on top of float bowl flange. See
arrow in Fig. 19.
SPARK PLUG READINGS
If possible, ride for a good distance to get a proper reading
on the spark plug(s). NEVER let engine idle for a long
period of time before checking spark plugs.
Carb Needles
The larger the number on the needle, the richer the
mixture. Needles with “-1” are richer off-idle.
Check needle goes here
Fig. 19
4. Tilt float bowl upside-down so float closes needle
completely. Using a machinists scale, measure
from the end of the float to the top of the bowl.
See Fig. 19. The float height should be set to
.500" (1/2").
Size
Part No.
Size
Part No.
Size
Part No.
3
8355
9
8364
13-1
8373
4
8356
9-1
8365
14
8374
5
8357
10
8366
14-1
8375
6
8358
10-1
8367
15
8376
6-1
8359
11
8368
15-1
8377
7
8360
11-1
8369
16
8378
7-1
8361
12
8370
16-1
8379
8
8362
12-1
8371
17
8380
8-1
8363
13
8372
Float adjustments are made by carefully bending
the small tab on the back of the float. See Fig.
20.
Main Jets
Size
Part No.
Size
Part No.
Size
Part No.
62
8140
70
8144
78
8148
64
8141
72
8145
80
8149
66
8142
74
8146
82
8150
68
8143
76
8147
84
8151
Fig. 20
Air Bleeds
By bending the tab outward (away from float) you will
lower the float level. Bending the tab inward will raise
the float level.
NOTE: Changing the float level will affect the
carburetor jetting. If the float level has been
readjusted, it may be necessary to retune the
carburetor.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 12 of 16
Size
Color
Part No.
Size
Color
Part No.
20
Purple
8170
40
Blue
8174
25
Black
8171
45
Green
8175
30
Gold
8172
50
Orange
8176
35
Red
8173
Rev. 8/03
CARB INTERNALS
3
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
5
1
4
2
5
7
8
9
Description
Required
8.32 x 3/4 cap screws
2
8.32 x 1/2 cap screw
1
M.A.T.
1
Cable bracket comp.
1
8.32 x 3/8 Phillips pan head
2
Bowl vent tube
1
Cap 38.40.42 B/B Chr
1
Cap gasket
1
Needle adj. Assembly
1
Needle 10-0-17.0
1
Needle spring
1
Slide assembly
38.40.42
8-32x3/8 Allen Hd Soc Screw 1
4.40 x 1/4 torx pan
1
Edelbrock
Part No.
8398
8410
8450
8305
8404
9091
8309
8304
8352
See page 11
8340
38-40=8354; 42=8451
8399
8403
23
16
10
14
13
11
18
21
19
12
12
6
21
19
57
22
58
20
28
27
59
20
26
29
52
32
54
55
29
34
51
47
53
49
48
30
31
46
39
40
41
42
34
35
36
37
56
45
33
43
44
45
©2003 Edelbrock Corporation
Brochure No. 63-0195
24
25
17
15
15
13
24
38
50
Page 13 of 16
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Spool
Cable wheel
Slide return spring
Throttle shaft
Stainless Steel flat washer
Choke assembly complete
Shaft bearing
Shaft clip
8.32 x 7/8 idle screw
Idle washer
Idle spring
Main jet 64-84
Idle air bleed 2550
4.40 x 1/4 soc screw
Bowl gasket
Float
Slosh plate
Bowl baffle
Float bowl
1
1
1
1
2
1
2
1
1
2
1
1
1
1
2
1
1
1
1
8341
8342
8346
9087
9089
8338
9089
8405
8400
8408
8351
See page 11
See page 11
8407
8327
8328
8318
8640
9090
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Needle & seat
Fuel inlet O-ring
Fuel inlet keeper
8.32 x 1/4 c/s
Fuel inlet
Pump bypass screw
Pattern nut
Stainless Steel flat washer
Bypass screw O-ring
Bowl plug O-ring
Bowl plug
8.32 x 5/8 soc c/s
8.32 x 3/4 soc c/s
4.40 x 3/8 torx pan screw
Float hinge pin
Pump check ball
Pump check needle
Pump plunger assembly
Plunger boot
Pump plunger (only)
8.32 x 1/2 button head
Stainless Steel flat washer
Pump return spring
Cotter pin
Pump lever
Pump link
1
2
1
1
1
1
1
1
1
1
1
2
2
2
1
1
1
1
1
1
2
2
1
1
1
1
8326
9093
9093
9093
9093
9094
9094
9089
9094
9095
9095
8401
8398
8328
8328
9096
9096
9097
9097
9098
9097
9089
9096
9099
9099
9099
Rev. 8/03
EXAMINE AND EVALUATE FOR THE FOLLOWING CONDITIONS:
Condition
Bike Performance
Plug Reading
Good Performance
Smooth idle, good acceleration, good fuel economy
Porcelain area of spark plug
should be white to a light tan
color with no flaking. Threaded
area will have a dark
discoloration.
Rich in the low-mid range
Rough idle, poor fuel economy, black smoke at idle
Porcelain and threaded area
will be black and sooty.
Lean low-mid range
Hard starting, poor throttle response, popping
through exhaust during deceleration.
Motor will only idle with enrichener on.
White porcelain, may be
flaking. Threaded area will be
clean.
Rich mid-wide open
Motor will fall off at higher RPMs. A slight
reduction of throttle will make engine pick up and
rev. If there is an extremely rich condition, motor will
sputter at wide-open throttle. Poor fuel economy.
Porcelain will be dark brown to
black in color and possibly
sooty. Threaded area will be
black and sooty.
NOTE: Careful, sometimes the rev limiter is mistaken
for this condition.
Lean mid-wide open
©2003 Edelbrock Corporation
Brochure No. 63-0195
Poor acceleration above half throttle. May pop
through air cleaner.
Page 14 of 16
Porcelain will be snow-white in
color with whisker-like
protrusions.
Rev. 8/03
TROUBLESHOOTING GUIDE
I.
POOR IDLE
1. Inconsistent idle rpm, too rich or too lean. Check the following:
a. Improper air bleed installed. See idle mixture adjustments.
b. Air leak. Check manifold to head seals and carb to manifold grommet/gasket.
c. Enrichener is not completely shut off.
II.
POOR 1/8-1/3 THROTTLE PERFORMANCE
1. Engine will not run smooth at steady throttle between 1/8 and 1/3 throttle. Runs too rich or too lean.
Check the following:
a. Improper needle setting. See "Off-idle to mid range adjustments.
b. Fuel tank caps not venting properly. Can cause pressure build up or vacuum in tank.
c. Air leak. Check manifold to head seals and carb to manifold grommet/gasket.
III.
POOR 1/3-full THROTTLE PERFORMANCE
1. Engine will not run smooth at steady throttle between 1/3 and 2/3 throttle. Runs too rich or too lean.
Check the following:
a.
b.
c.
d.
e.
f.
Incorrect needle size. See "Needle size adjustments"
Incorrect main jet size. See "Main jet adjustments"
Fuel tank cap no venting properly. Can cause pressure build up or vacuum in tank.
Clogged main jet. May perform good at lower throttle openings where fuel is no in great demand.
Clogged or dirty air filter may restrict airflow at higher throttle openings.
Clogged petcock filter or in-line fuel filter.
If problems continue, please contact Edelbrock Toll-Free Tech Line at: 877-888-7504 ext. 2. 8:00am-12:30pm, 1:30
pm-5:00pm, Monday through Friday, Pacific Standard Time. Tech service is also available via internet at
www.edelbrock.com. E-mails will be answered within 72 hours of being received.
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 15 of 16
Rev. 8/03
WARRANTY POLICY
Edelbrock Carburetors and all parts included in carburetor kits are warranted to the original purchaser to be free of
manufacturing defects in materials and workmanship for a period of one (1) year from the original date of purchase. Any
part that fails to conform to these conditions will be repaired or replaced at the discretion of Edelbrock, upon receipt of
the defective part within the one (1) year warranty period.
In the event a part has been rendered defective, Edelbrock must be notified prior to the return of the defective part. A
Return Authorization Number MUST BE OBTAINED prior to the return of any defective parts. A part that is suspected to be
defective must not be replaced without prior authorization from Edelbrock. Edelbrock will not be liable for any
consequential or incidental damages resulting from the failure of any Edelbrock part, the breach of any warranties, the
failure to deliver, delay in delivery, delivery in non-conforming condition, or for any other breach of duty between Edelbrock
and a customer.
All warranties will be void under any of the following conditions:
1. Merchandise was improperly installed or used in an abnormal application.
2. Merchandise has been modified or altered in any way.
DISCLAIMER
It is the sole responsibility of the user to determine the suitability of the product for his/her use, and the user shall assume
all legal, personal injury risk and liability and all other obligations, duties and risks associated therewith.
Edelbrock will not be liable for any modifications made to carburetors designed to meet emissions standards. Any
modifications to these products will void certification and all warranties they may carry.
'
Please contact Edelbrock with any questions at 1-877-888-7504 ext. 2, 8:00am-12:30pm and 1:30pm5:00pm, Monday-Friday, Pacific Standard Time.
Edelbrock Corporation
Carburetor Division
1320 Buena Vista Street
San Jacinto, CA 92583
Phone (909) 654-6677 ext. 2
Fax (909) 654-4698
Toll Free Tech Line 1-877-888-7504 ext. 2
©2003 Edelbrock Corporation
Brochure No. 63-0195
Page 16 of 16
Rev. 8/03
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