User manual | DualCarb install

Installation and Tuning Instructions for Dual Carburetors
Edelbrock Motorcycle Carburetor Division
1320 Buena Vista Street,
San Jacinto, California 92583
Toll-Free Tech Line: (877) 888-7504 • FAX (909) 654-4698
Table of Contents
Introduction..............................................................................................................1
Parts Required for Installation....................................................................................2
Installation ...............................................................................................................5
Manifold/Carburetor Installation.................................................................................5
Throttle Cable Connections ........................................................................................6
Air Cleaner Installation ..............................................................................................6
Operation .................................................................................................................6
Starting Procedure ....................................................................................................6
Adjusting Carburetor .................................................................................................7
Idle Adjustment ........................................................................................................7
Idle to Mid-Range Adjustment ................................................................................7-8
Needle Size Adjustments ......................................................................................9-10
Spark Plug Readings ...............................................................................................11
General Information ................................................................................................11
Float Adjustment.....................................................................................................11
Trouble Shooting ............................................................................................... 12-13
Gas Cap Drilling Procedure ......................................................................................13
Warranty ................................................................................................................13
Disclaimer ..............................................................................................................13
Carburetor Exploded View .......................................................................................14
INTRODUCTION
The Edelbrock Performer Series
Carburetor is a smooth bore, gravity
fed, carburetor, with a float operated
fuel valve, a variable venturi and a
throttle stop screw for idle speed
adjustment. The enricher is a lever or
cable operated valve allowing fuel to be
drawn directly from the float bowl and
enters the venturi directly behind the
slide. This system WILL NOT cause the
idle speed to increase when engaged.
EDELBROCK DUAL CARBURETOR
KIT REQUIRE A CAMSHAFT WITH
NO LESS THAN 240 DURATION ON
BOTH INTAKE AND EXHAUST AND
40 DEGREES OF OVERLAP. Failure to
use an appropriate cam will result high
manifold vacuum making the throttle
very stiff.
The EPS venturi design increases air
velocity and air flow (CFM).The common
theory that a bigger carburetor is better,
is not the case when it comes to the
EPS. When a venturi is too big air
velocity is lost, which means the ability
to lift and atomize the fuel is lost
creating what is known as “flat spots”.
Please, when choosing a venturi size
use the chart we have provided and if a
different size is desired, contact
Edelbrock for recommendations.
80-95”
34mm
96-113” 38mm
114-up
40mm
IMPORTANT!
Parts Required for Installation
Read Before beginning Installation
To complete this installation you must
have all of the following parts:
1. Edelbrock Dual-Carburetor Kit
2. Edelbrock Dual-Carb Intake
Manifold
3. Throttle Cables
4. Dual-Carburetor Air Cleaner
Check the following listings to be sure
that you have the right parts to
complete the installation on your bike.
Recommended venturi sizes are as
follows:
#8635
#8636
#8637
Important Note: Highly modified
engines may require different
combinations than listed above. In these
cases, please call Edelbrock for
assistance.
Note: It is recommended a high-flow,
non-vacuum operated petcock be used
with
all
dual
carb
set-up
Edelbrock Dual-Carburetor Kits
Kits include chrome-plated carbs,
mounting hardware, fuel line,
metering adjustment tools and
spare needles for tuning.
Dual-Carburetor Air Cleaner
Designed for two Edelbrock carbs, this
oval air cleaner has a billet aluminum
top and base plate and includes a K&N
2-3/4" element.
#8627(with Edelbrock Logo)
#8638(without logo)
Throttle Cables
PRECAUTIONS
These cables are designed for the DualCarb set-up. To choose the correct
cables:
1) Measure stock throttle cable housing.
2) Add 10 inches.
3) Round up to closest size.
Several Warnings and precautions
should be taken before and during
installation:
Description
35" 40" 45" 50"
1984-95 Black Teflon Cables
8268 8276 8271 8607
WARNING! GASOLINE IS EXTREMELY
FLAMMABLE AND HIGHLY EXPLOSIVE,
IT CAN ALSO BE VERY HARMFUL IF
INHALED. DO NOT SMOKE! PERFORM
INSTALLATION IN A WELL VENTILATED
AREA. KEEP OPEN FLAME OR SPARKS
AWAY FROM GASOLINE AT ALL TIMES.
1984-95 Stainless Steel Cables
8269 8277 8272 8608
1996-up Black Teflon Cables
8680 8682 8684 8686
1996-up Stainless Steel Cables
8681 8683 8685 8687
Dual-Carb 3-Piece Intake Manifolds
These chrome-plated intakes are
available in four flange thicknesses for
various cylinder head/barrel length
combinations.
Cyl.Ht.
Stock
-.050
-.175
+.075
+.200
+.265
ROUND
PORT
8601
8621
3087
8622
8623
3127
SQUARE
PORT
8602
8624
3083
8625
8626
3124
*IF YOU NEED ASSISTANCE WHEN
CHOOSING A MANIFOLD FOR YOUR
MOTOR,
PLEASE REFER TO OUR
WEBSITE WWW.EDELBROCK.COM, OR
CALL OUR TECH LINE AT 877-888-7504
OPTION # 2.
1.)
Check fuel valve, making sure it
is completely OFF!
2.)
Disconnect battery to eliminate
the possibility of sparks or
accidentally engaging the starter.
3.)
Read instructions thoroughly and
carefully, making sure all are completely
understood
before
beginning
installation. Please call with any
questions.
Dual-Carburetor and Manifold
Installation
Figure 2.
NOTE: THESE DIRECTIONS NEED TO
BE FOLLOWED IN EXACT ORDER TO
ENSURE PROPER INSTALLATION. IF
ORDER IS NOT FOLLOWED, PROBLEMS
MAY OCCUR DURING INSTALLATION.
1.)
Remove stock manifold and
hardware, including throttle cables.
2.)
Install manifold bracket to front
cylinder head.
A.) (Big Twin Evos 1984-1992) Install
Manifold bracket to front cylinder using
the (2) 5/16-18 X 1-1/2" chrome-plated
button head cap screws, (2) 5/16-1/2"
reducers and (2) spacers (see figure 1).
DO NOT TIGHTEN OR CONNECT TO
REAR CYLINDER AT THIS TIME.
Figure 1.
3.)
Assemble carburetors to manifold
using (2) manifold gaskets, (4) 5/16-18
X 1 chrome plated ferry head bolts and
(4) 5/16 washers.
CAUTION: AN IMPROPERLY MOUNTED
CARBURETOR OR MANIFOLD COULD
COME LOOSE FROM THE ENGINE,
RESULTING IN AIR LEAKS/POOR
PERFORMANCE AND COULD CAUSE
PERMANENT DAMAGE TO ENGINE.
W A R N I N G ! AN IMPROPERLY
MOUNTED CARBURETOR OR MANIFOLD
COULD BREAK FREE. IF MOTORCYCLE
WOULD FALL AND SUSTAIN DAMAGE IN
AN ACCIDENT, THIS COULD CAUSE AN
UNWARRANTED
RELEASE
OF
GASOLINE, CREATING A FIRE HAZARD
AND POTENTIAL PERSONAL INJURY TO
YOU OR OTHERS.
B.) (Big Twin Evos 1993-1999 and 1999later Twin Cam) Install Manifold bracket
to front cylinder using the (2) 1/2"-13 X
1-1/2" chrome plated banjo bolts, (6)
fiber washers. See Figure 2. DO NOT
TIGHTEN OR CONNECT TO REAR
CYLINDER AT THIS TIME.
4.) Prepare manifold/carburetor
assembly for installation.
A.) Install (2) 5/16-18 X 1” Black ferry
head bolts and (2) 5/16 washers into
the lower (left side of engine) manifold
mounting holes of the front and rear
cylinders. Only thread in 2-3 threads. A
small amount of grease can be used to
hold the washer against the head of the
bolt for easier manifold installation.
B.) Clean intake port surfaces on
cylinder heads to ensure proper
manifold to head seal.
C.) Install manifold flanges, making sure
the flange marked “F” is on the front
port and the flange marked “R” is on the
rear port. See Figure 3. Install rubber
seals with tapered side toward flange.
Figure 3.
6.)
Secure manifold to mounting
bracket using the two rubber washers,
sleeve cup washer and 3/8 button head
bolt. Place one rubber washer on top
manifold and under bracket. Place
second washer on top of mounting
bracket and place steel sleeve through
center of rubber washers. Place chrome
cup washer over rubber washer and
insert bolt (see figure 4) with Blue Lctite
(or equivalent) and tighten.
Figure 4.
NOTE: A LIGHT FILM OF GREASE OR
HIGH TEMPERATURE SILICONE WILL
HELP ENSURE A PROPER SEAL. IF
MANIFOLD IS BEING RE-INSTALLED,
WE RECOMMEND REPLACING THE
MANIFOLD RUBBERS/SEALS, TO
ENSURE A PROPER SEAL AND NO AIR
LEAKS. If your manifold uses round
seals, you can replace them with stock
seals from a dealership.
5.) Install Manifold
A.) Holding manifold bracket up out of
the way, carefully insert the
manifold/carburetor assembly into
place, making sure the 5/16 washers
stay on top of the flanges.
B.) Insert (2) 5/16-18 X 1” socket head
bolts and (2) 5/16 washers into the
remaining manifold mount holes in
cylinder heads. Right side of engine.
C.) Snug manifold mounting bolts
slightly, DO NOT COMPLETELY
TIGHTEN!
A.) Big Twin EVO 1984-1992 Use step
2A for proper procedure, only apply to
the rear cylinder.
B.) Big Twin EVO 1990-1999 and 1999later Twin Cam, Use step 2B for proper
procedure, only apply to rear cylinder.
Use remaining breather banjo and point
it toward the front of the motorcycle.
C.) Tighten manifold bracket mounting
bolts.
7.) Install fuel line and connect VOES
(if equipped).
NOTE: EDELBROCK
CARBURETORS
REQUIRE THE USE OF A TWO CABLE
(PUSH-PULL) THROTTLE ASSEMBLY. IF
YOUR BIKE IS NOT EQUIPPED WITH
THIS TYPE, EDELBROCK OFFERS A
TWO-CABLE THROTTLE ASSEMBLY.
8.) Throttle cable connections:
A.) Double check cable selection, using
chart found in the “Throttle Cable
Requirement” section of this manual
D.) Insert the throttle cable in the 4:00
position and insert the Idle cable in the
1:00 position (see figure 6).
Figure 6.
NOTE: CABLE SHOULD BE ROUTED
DOWN THE LEFT HAND SIDE OF
MOTORCYCLE.
NOTE: THROTTLE ASSEMBLY MUST BE
ASSEMBLED CORRECTLY AND WORK
FREELY TO PREVENT POSSIBLE
STICKING OF THE THROTTLE DURING
OPERATION. MAKE SURE CABLES ARE
FREE OF TIGHT BENDS AND HAVE
PLENTY OF FREE PLAY TO MINIMIZE
CABLE FRICTION.
WARNING! IF THE THROTTLE DOES
NOT WORK FREELY, IT MAY STICK
OPEN CAUSING LOSS OF CONTROL OF
THE MOTORCYCLE AND PERSONAL
INJURY TO YOU AND OTHERS.
B.) Loosen cable free play adjustment
locknuts and thread adjusting screw so
there are no threads exposed, this will
give you the maximum amount of free
play.
C.) Loosen the inside cable clamp by
loosening the 3/32 allen screw on the
left side of the cable bracket (see figure
5).
Figure 5.
NOTE: ALWAYS USE A MEDIUM HIGH
HEAT THREAD LOCKING COMPOUND
ON ALL MOUNT BOLTS AND SCREWS.
THIS WILL PREVENT HARDWARE FROM
VIBRATING LOOSE.
AIR CLEANER INSTALLATION
1.)
Prepare backing plate for
installation by installing the brass 3/8"
barb fitting into back.
2.) Using (2) air cleaner gaskets, (6)
1/4"-20 X 1/2" button head cap screws
mount backing plate to carburetors
using blue Loctite.
3.) Connect breather line to 3/8 barb.
A.) (Big Twin EVO 1984-1992) Use 5/16
Breather line provided to connect
existing breather tube to 3/8 barb
fitting.
B.) (Big Twin EVO 1993-1999, 1999later Twin Cam) Connect 5/16 banjos
using the 5/16 plastic tee. Connect tee
to 5/16 barb.
4.) Install element and cover using (2)
1/4"-20 X 3/4" flat socket head cap
screws with blue Loctite.
CARBURETOR OPERATION
Figure 7.
Starting Procedure
The Edelbrock dual carburetor does not
have a conventional choke. Instead, a
fuel enrichment device is used for
starting. This device uses a separate
fuel pick-up tube to enrichen the
mixture. This WILL NOT cause the idle
to increase. The enricher is for starting
purposes only, continued use will cause
an excessively rich condition or fouled
spark plugs.
Cold Starts:
1.)
Open Fuel Petcock.
NOTE: WHEN MOTORCYCLE IS NOT
RUNNING, THE FUEL PETCOCK SHOULD
ALWAYS BE TURNED OFF TO PREVENT
POSSIBLE LEAKAGE.
CAUTION: Not Closing the Fuel Petcock
May Cause GASOLINE to LEAK PAST
THE NEEDLE AND SEAT and MAY
FLOOD THE ENGINE, CAUSING DAMAGE
AND CREATING A FIRE HAZARD.
NOTE: ENRICHER CAN BE ROTATED
EITHER DIRECTION AND SHOULD ONLY
BE ROTATED TO THE 6:00 OR 12:00
POSITION. (See figure 7).
2.)
Turn on ignition.
3.) Turn enrichener lever to 6:00 or
12:00 position. Twist throttle two times
to activate accelerator pump. With
throttle closed engage starter, if engine
fails to fire, slightly open the throttle
and continue engaging starter until
engine fires. Once the engine has fired
return the enricher lever back to the
9:00 position and warm to operating
temperature by holding the throttle at
1000-1200 RPM for 2 minutes or several
miles.
N O T E : FOR PROBLEMS WITH
STARTING SEE TROUBLESHOOTING
TIPS AT THE END OF THIS MANUAL.
HOT STARTS
1.)
Figure 8.
Open Fuel Petcock.
NOTE: WHEN MOTORCYCLE IS NOT
RUNNING, THE FUEL PETCOCK SHOULD
ALWAYS BE TURNED OFF TO PREVENT
POSSIBLE LEAKAGE.
CAUTION: Not Closing the Fuel Petcock
May Cause GASOLINE to LEAK PAST
THE NEEDLE AND SEAT and MAY
FLOOD THE ENGINE, CAUSING DAMAGE
AND CREATING A FIRE HAZARD.
2.)
Turn on ignition.
3.)
With the throttle closed engage
starter.
4.)
If engine fails to start
immediately, open throttle slightly and
continue to kick or engage starter until
engine fires.
N O T E : FOR PROBLEMS WITH
STARTING SEE TROUBLESHOOTING
TIPS AT THE END OF THIS BOOKLET.
ADJUSTING CARBURETOR
N O T E : ALL MIXTURE OR NEEDLE
ADJUSTMENTS SHOULD BE DONE
EVENLY.
IDLE 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
needle adjuster upon tuning the low to
mid range. The idle adjustment screw is
located on the cable wheel where the
throttle cables attach. (See figure 8)
Edelbrock adjusts this screw to a
position that should allow the bike to
idle upon initial start-up.
1.)
Start engine and warm for
approximately 2-3 minutes.
2.)
Initially adjust to obtain 900-1000
RPM by using the 9/64 hex wrench
provided.
N O T E : IDLE SPEED WILL CHANGE
WHEN ADJUSTMENTS ARE MADE TO
THE NEEDLE ADJUSTER. THIS WILL
REQUIRE THE REPEAT OF STEPS ONE
(1) AND TWO (2).
Mixture Adjustment (IDLE TO
MIDRANGE, 800-2500 RPM)
All Edelbrock Performance Carburetors
come preset for use on a stock based
engine with a performance camshaft
(240 degrees or better duration and 40
degrees or better of over-lap) and
performance exhaust with baffles.
Depending on the modifications that
have been made to your motorcycle a
slight adjustment to the air/fuel mixture
may be necessary.
Before attempting to tune your
Edelbrock carburetors, a change of
spark plugs is recommended. This will
make it a lot easier to tune and if you
haven’t done so in a while, this will also
give you better performance.
NOTE: IF LOW IDLE SPEED CANNOT BE
OBTAINED OR THE ENRICHER HAS TO
BE ON FOR ENGINE TO RUN, THIS IS
AN INDICATION OF A LEAN CONDITION
IN THE IDLE TO MID-RANGE, OR
POSSIBLY AN AIR LEAK IN THE INTAKE
TRACT.
NOTE: IF BIKE IDLES, BUT HAS A HINT
OF BLACK SMOKE, MAKE SURE THE
ENRICHER IS COMPLETELY OFF. IF THE
ENRICHER IS OFF AND THE SMOKE
PERSISTS, THIS IS AN INDICATION,
THAT A RICH CONDITION EXISTS IN
THE IDLE TO MID-RANGE.
INITIAL RIDE
The motorcycle’s performance is usually
the best way to tune the carburetor.
Due to different grades of gasoline,
gasoline additives and different ignition
settings, plug readings may differ from
engine to engine.
1.)
After completing the engine idle
adjustment, it is now ready for an
initial test ride.
Ride motorcycle paying close attention
to the RPM ranges of 1000-2500. In this
RPM range things to watch for are:
Lean Condition
A.)
Hard Starting
B.)
Lag in acceleration
C.)
Popping or back firing through
the intake or exhaust on deceleration.
D.)
Erratic idle or won’t idle down to
900-1000 RPM
NOTE: BEFORE ADJUSTING FOR THIS
CONDITION, CHECK FOR INTAKE AND
EXHAUST LEAKS. THESE LEAKS HAVE
SIMILAR SYMPTOMS.
Rich Condition
A.)
B.)
C.)
D.)
Black smoke at idle
Lazy acceleration
Poor mileage
Poor low-rpm cruise
NOTE: BEFORE MAKING ADJUSTMENT
FOR THIS CONDITION MAKE SURE
ENRICHER IS COMPLETELY OFF.
IDLE TO MID-RANGE AIR/FUEL
MIXTURE ADJUSTMENT
All idle to mid range adjustments are
made by rotating the center slot of the
needle adjuster right (Clockwise) to
richen the mixture or Left (Counterclockwise) to lean the mixture. These
adjustments are referred to as “clicks”.
Each click equals a 1/4 turn of the
screwdriver. The usable range is
approximately thirty (30) clicks from full
rich. Always adjust carburetors equally.
Base setting for Edelbrock dual
carburetors is K-8 Needles @ 10 clicks.
N O T E : WE AT EDELBROCK HAVE
FOUND THAT ADJUSTING THE
MIXTURE TO A SLIGHTLY RICH
CONDITION (SMALL AMOUNT OF
BLACK SMOKE AT IDLE), THEN LEAN
THE MIXTURE 2 CLICKS, GENERALLY IS
A GOOD BASE TO FINE TUNE FROM.
CAUTION:
WHEN
MAKING
ADJUSTMENTS TO NEEDLE ADJUSTER,
DO NOT LOOSEN OUTER COLLAR AS IT
MAY BACK OUT CAUSING AN
EXCESSIVE RICH CONDITION OR
POSSIBLE
DAMAGE
TO
THE
CARBURETOR.
N O T E : USE ONE OF THE THREE
METHODS DESCRIBED FOLLOWING.
METHOD #1
1.)
Using the 3/16 hex wrench
provided, remove cap plugs from caps,
located on top of the carburetor.
2.) Install Mixture Adjustment Tool
(Included) into the cap plug hole, using
a 7/16 wrench. Snug slightly. With the
engine off, open the throttle to the full
position and lock it down, using the
thumb lock on the underside of the
throttle housing.
WARNING! DO NOT OVER TIGHTEN
AS DAMAGE MAY OCCUR TO CAP.
3.) Make adjustment by pushing down
and turning the red knob until it
engages and some resistance is felt.
Once resistance is felt DO NOT continue
rotating knob. Now make adjustment
according to the
following:
TO MAKE RICHER 0-1/3 THROTTLE
(MORE FUEL) 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.
N O T E : IF PROPER ADJUSTMENT
CANNOT BE OBTAINED THROUGH THE
STANDARD RANGE OF ADJUSTMENT
SEE
SECTION
“NEEDLE
SIZE
ADJUSTMENTS” LATER IN THIS
MANUAL.
TO MAKE LEANER 0-1/3 THROTTLE
(LESS FUEL) Pushing down turn the red
adjuster knob to the LEFT (CounterClockwise) one (1) or two (2) clicks
depending on the severity of the rich
condition.
4.) Release red knob and throttle
lockdown.
Evaluate performance and repeat
process, if necessary.
METHOD #2
1.)
Using the 3/16 hex wrench
provided, remove cap plugs from caps,
located on top of the carburetor.
2.) Locate the center slot of the needle
adjuster, insert a 3/16” straight
screwdriver and make adjustment as
follows:
TO MAKE RICHER 0-1/3 THROTTLE
(MORE FUEL) Turn center adjuster to
the RIGHT (Clockwise) one (1) or two
(2) clicks depending on the severity of
the lean condition.
NOTE: IF PROPER ADJUSTMENT
CANNOT BE OBTAINED THROUGH THE
STANDARD RANGE OF ADJUSTMENT
SEE
SECTION
“NEEDLE
SIZE
ADJUSTMENTS” LATER IN THIS
MANUAL.
TO MAKE LEANER 0-1/3 THROTTLE
(LESS FUEL) Turn adjuster to the LEFT
(Counter-Clockwise) one (1) or two (2)
clicks depending on the severity of the
rich condition.
3.)
Reinstall cap plug and tighten
carefully.
4.)
Evaluate performance and repeat
process if necessary.
METHOD #3
1.)
Using a 3/16” hex cordless
screwdriver bit (not included) and a 1/4”
wrench remove cap plugs.
2.)
Open throttle to the full or wide
open position, Insert a 3/16” straight
screwdriver bit, aligning it in the center
slot of the needle adjuster, make
adjustment as follows:
3.)
Make adjustment:
TO MAKE RICHER 0-1/3 THROTTLE
(MORE FUEL) Turn center adjuster to
the RIGHT (Clockwise) one (1) or two
(2) clicks depending on the severity of
the lean condition.
N O T E : IF PROPER ADJUSTMENT
CANNOT BE OBTAINED THROUGH THE
STANDARD RANGE OF ADJUSTMENT
SEE
SECTION
“NEEDLE
SIZE
ADJUSTMENTS” LATER IN THIS
MANUAL.
TO MAKE LEANER 0-1/3 THROTTLE
(LESS FUEL) Turn adjuster to the LEFT
(Counter-Clockwise) one (1) or two (2)
clicks depending on the severity of the
rich condition.
4.)
Re-install cap plugs and tighten
carefully.
5.)
Close throttle
6.)
Evaluate performance and repeat
process if necessary.
Mixture Adjustment (Mid-Range to Full
Throttle 2500-6000 RPM)
This adjustment is made by removing
the slide and changing the needle. All
Carburetors come pre-jetted, with a K-8
needle installed. We have also included
K-7 and K-9 needles. The higher the
number the richer the needle, from 1/3
to full throttle. A needle change may be
required for different engine
combinations.
Ride motorcycle paying close attention
to the RPM ranges of 2500-6000. In this
RPM range things to watch for are:
NOTE: CLOSE ATTENTION SHOULD BE
PAID NOT TO OVER-REV THE ENGINE.
MOST MOTORCYCLES HAVE A BUILT IN
REV LIMITER, WHICH ELIMINATES THE
POSSIBILITY OF THIS HAPPENING. A
REV LIMITER CAN ALSO SOMETIMES BE
MISTAKEN FOR A FLAT SPOT IN THE
HIGHER RPM RANGES. DETERMINE
WHETHER OR NOT THIS IS THE CASE
BEFORE MAKING ADJUSTMENTS FOR
THIS CONDITION.
WARNING: OVER-REVVING THE
ENGINE CAN CAUSE PERMANENT
DAMAGE.
Lean Condition
A.)
Will not rev over 4000-5000 RPM
B.)
Poor acceleration when throttle is
rolled on from 4000 RPM
Rich Condition
A.)
With throttle at full position
power-band falls off, rotate throttle back
and engine RPM’s come up and
motorcycle accelerates slightly.
B.)
Black smoke from exhaust
C.)
Lazy acceleration.
Adjustments
1.)
Remove the three cap screws
from each carburetor and lift cap slightly
separating the cap from the cable
bracket. (see picture)
2.) Remove screw attaching actuator
strip to inside wheel using a T-10 Torx
bit. See figure 9.
Figure 9.
3.)
Remove slide assemblies from
carburetors.
4.)
Using
a
3/16”
straight
screwdriver start turning the center slot
to the right (clockwise) counting clicks
or 1/4 turns as you go. See figure 10.
Figure 10.
the head of the needle. Insert
needle with spring into the slide,
aligning the notch on the needle
with groove in slide. Insert needle
adjuster actuator pin aligning roll
pin with groove in slide.
7.)
Install needle adjuster assembly.
See figure 11.
Figure 11.
N O T E : THIS ALLOWS YOU TO
REPOSITION THE NEW NEEDLE IN THE
SAME LOCATION FOR IDLE-MID RANGE
ADJUSTMENT. SOME ADJUSTMENT MAY
NEED TO BE MADE TO THIS SETTING
AFTER MOTORCYCLE HAS BEEN TEST
RIDDEN AGAIN.
5.)
Using a large bladed straight
screwdriver remove needle adjuster
assembly and needle from slide.
N O T E : TO MAKE RICHER 1/3-FULL
THROTTLE (MORE FUEL) Read number
located on the lower end of the needle.
To make richer you would go to the
next number. EXAMPLE: The factory
installed needles are K-8’s, you would
go to K-9’s for a richer mixture.
N O T E : TO MAKE LEANER 1/3-FULL
THROTTLE (LESS FUEL) Read number
located on the lower end of the needle.
To make leaner you would go to the
next lower number. EXAMPLE: The
factory installed needles are K-8’s, you
would go to K-7’s for a leaner mixture.
6.) Place needle spring on desired
needle with the small end towards
NOTE: NEEDLE ADJUSTER MUST BE
COMPLETELY
TIGHTENED
TO
ELIMINATE THE POSSIBILITY OF IT
BACKING OUT DURING OPERATION. (A
DROP OF LOCTITE 642 ABOVE THE
FOUR CROSS-DRILLED HOLES IS
RECOMMENDED.) IF THIS HAPPENS,
THE MOTORCYCLE WILL BECOME VERY
RICH AND WILL NOT RUN PROPERLY.
8.)
Using a 3/16 screwdriver rotate
center needle adjuster (see figure 10)
all the way to the right (clockwise) until
it stops. Rotate back left (counterclockwise) to the first click. Now rotate
left (counter-clockwise) counting clicks
(one (1) click equals a 1/4 turn), until
the number acquired from step # 6 is
reached.
N O T E : WHEN REINSTALLING CAP,
ROTATE CABLE WHEEL BACK TO AVOID
CLAMPING THE CAP DOWN ON THE
IDLE ADJUSTMENT SCREW. CLAMPING
DOWN ON THIS SCREW WILL CAUSE
PERMANENT DAMAGE TO THE
CARBURETOR.
9.)
When finished repeat steps 1-5 in
reverse order.
Spark Plug Readings
1.
If possible ride the motorcycle for
a good distance to get a proper reading
on the spark plugs. Never let motorcycle
idle for a long period of time before
checking spark plugs.
Examine and evaluate for the following
conditions:
Condition-Good Performance
Bike Performance: Smooth idle, Good
acceleration, Good fuel economy.
Plug Reading: Threaded metal area
surrounding the porcelain will have a
little dark discoloration. Porcelain area
of spark plug should be a light tan to
white color with no flaking.
Condition-Rich in the Low-Mid
Range
Bike Performance: There will be a hint
of black smoke at idle, rough idle, poor
fuel economy, fouled spark plugs.
Plug Reading: Threaded metal area
surrounding porcelain will be dark black
and very sooty.
Condition-Lean Low-Mid Range
Bike Performance: Won’t run without
enricher turned on.
Plug Reading: NONE.
Condition-Rich Mid-Full Range
Bike Performance: Bike will fall off at
higher RPM’s. A slight reduction of
throttle will make motorcycle pick up
and rev all the way out. Poor fuel
economy.
N O T E : Careful, sometimes the rev
limiter is mistaken for this condition.
W A R N I N G ! OVER-REVVING THE
MOTOR CAN CAUSE SERIOUS DAMAGE!
Plug Reading: Porcelain area of spark
plug will be brown to dark black and
sometimes sooty.
Condition-Lean Mid-Full Range
Bike Performance: Poor acceleration
from half throttle to full throttle. Pops
and stutters above half throttle.
Plug Reading: Porcelain will be white
with small whisker-like protrusions.
WARNING! CONTINUED OPERATION
IN THIS CONDITION CAN RESULT IN
SERIOUS DAMAGE TO THE MOTOR!
GENERAL INFORMATION
Float Adjustment
1.)
Remove carburetor.
2.)
Remove four (4) float bowl
sockethead cap screws from each
carburetor body.
3.)
Turn float bowls upside-down
and measure float level as shown in
figure 12.
Figure 12.
NOTE: FUEL LEVEL SHOULD RISE TO
THE MIDDLE OF THE NEEDLE AND
SEAT.
WARNING! GASOLINE IS EXTREMELY
FLAMMABLE AND HIGHLY EXPLOSIVE,
IT CAN ALSO BE VERY HARMFUL IF
INHALED. DO NOT SMOKE AND
PERFORM INSTALLATION IN A WELL
VENTILATED AREA. KEEP OPEN FLAME
OR SPARKS AWAY FROM GASOLINE AT
ALL TIMES.
4.)
Float level adjustments are made
by carefully bending the small tab
located on the back of the float.
A.)
Bending tab in raises float level.
B.)
Bending tab out lowers float
level.
4.) Repeat step #3 after adjustments
have been made.
6.) Repeat steps 1-2 in reverse order.
Accelerator Pump Adjustment
The new Edelbrock EPS Dual-Carb setups include and accelerator pump on
the inboard carburetor only. The pump
bypass screw located on the left side of
the float bowl controls the amount of
fuel the pump will deliver to the venturi
during rapid throttle opening. The
bypass screw is factory set at 1 turn out
from bottom. The further in the screw
is set, the more fuel will be delivered. It
is recommended that the bypass screw
be set after the needles have been set
to a desired position as the accelerator
pump works with the main fuel circuit.
To adjust bypass screw loosen 5/16 nut
and make adjustments to screw as
shown in figure 12. It is recommended
adjustments be made in 1/8 turn
increments at a time. Tighten 5/16” nut
when adjustments are final. When the
pump bypass screw is properly set there
should not be any hesitation in the
throttle response during rapid throttle
opening. The accelerator pump may
also be used to prime a cold motor
before starting by pumping the throttle
a couple of times.
Figure 12.
TROUBLESHOOTING
Problem
Check For
Remedy
Fuel Overflow
1.Loose float bowl screws
2.Damaged float bowl gasket
3.Damaged float assembly
4.Worn or dirty needle and seat
5.Improper fuel level in float bowl
6.Restricted fuel tank vent system
1.Tighten screws
2. Replace gasket
3.Replace float assembly
4.Clean or replace needle and seat
5.Adjust float tab for correct fuel level
6.Drill or replace gas cap
RESTRICTED FUEL FLOW
Restricted fuel tank vent system
1. Correct restricted hose/ Replace vapor valve
Restricted fuel supply line
2. Correct or replace fuel supply line
Particle contamination in fuel inlet cavity 3. Clean or clear cavity
Worn or dirty needle and seat
4. Clean or replace needle and seat
Improper fuel level in float bowl
5. Adjust float tab for correct fuel level
POOR IDLING
Idle speed improperly adjusted
Inlet system air leak (faster idling)
Enricher valve not seating or leaking
Leaking shaft o-rings (faster idling)
Erratic Idle (non-constant)
POOR FUEL ECONOMY
1.Excessive use of enricher system
2.Enricher valve not seated or leaking
1.Adjust operating idle speed
2. Correct as required
3. Adjust, clean or replace choke o-rings
4. Replace shaft o-rings
5. Adjust low speed air/fuel mixture
1. Limit use to start-up only
2. Adjust, clean or replace choke o-rings
3.Dirty air cleaner element
4.Restricted fuel tank vent system
5.High speed riding style
6.Idle speed improperly adjusted
7.Fuel level too high
8.Plugged or restricted bowl vents
9.Worn or damaged needle
10. Too rich fuel mixture
(non emissions models only)
POOR ACCELERATION
1.Throttle cables misaligned
2. Inlet system air leak
3. Restricted fuel tank vent system
4. Restricted fuel supply passages
5. Plugged bowl vents
6. Enricher valve not seated or leaking
7. Worn or damaged needle
8. Fuel level too low
9. Fuel mixture too lean
(non emissions models only)
10. Slide not opening completely
HARD STARTING
3. Clean or replace as required
4. Correct restricted hose / Replace vapor valve /
Drill gas cap for proper venting
5. Modify riding habits
6. Adjust operating idle speed
7. Adjust float level
8. Clean and clear passages
9. Replace needle
10. Lean mixture out
(non emissions models only)
1. Adjust throttle cables
2. Correct as required
3. Correct restricted hose / Replace vapor valve /
Drill gas cap for proper venting
4. Clean and clear passages
5. Clean and clear passages
6. Adjust, clean or replace choke o-rings
7. Replace needle
8. Adjust float level
9. Richen fuel mixture
(non emissions models only)
10.Adjust throttle cables
1.Enricher system plugged, not working 1. Adjust, clean or replace or improperly operated choke o-rings /
Read “START UP” inst.
2. Inlet system air leak
2. Correct as required
3. Fuel overflow
3. See “FUEL OVERFLOW TROUBLE SHOOTING”
4.Fuel restricted
4. See “RESTRICTED FUEL FLOW TROUBLE SHOOTING”
5. Lean low speed air/fuel mixture
5. See “TUNING INSTRUCTIONS”
POOR PERFORMANCE ON ROAD
1.Idle speed improperly adjusted
2. Inlet system air leak
3. Restricted fuel tank vent system
4. Dirty or damaged air cleaner element
5. Enricher valve not seated or leaking
6.Restricted fuel supply
7.Plugged float bowl vents
8.Worn or damaged needle
9.Improper fuel mixture
10. Slide not opening completely
1. Adjust operating idle speed
2. Correct as required
3. Correct restricted hose / Replace vapor valve
4. Clean or replace
5. Adjust, clean or replace choke o-rings
6. See “RESTRICTED FUEL FLOW TROUBLESHOOTING”
7. Clean and clear passages
8. Replace needle
9. See “TUNING INSTRUCTIONS” (non emissions models only)
10.Adjust throttle cables
If problems continue please give our technical staff a call at (877) 888-7504 option # 2 Mon.-Fri.
8:00AM to 12:30 PM, 1:30 PM to 5:00 PM Pacific Standard Time.
NOTE: SOME HARLEY-DAVIDSON AND AFTERMARKET GAS CAPS DO NOT VENT
PROPERLY. THESE GAS CAPS CAN CAUSE NUMEROUS PROBLEMS. WE AT EDELBROCK
STRONGLY RECOMMEND DRILLING A SMALL .075"-.100" HOLE IN THE CENTER OF
THE GAS CAP TO RELIEVE PRESSURE.
1.Remove gas cap from motorcycle.
2.Drill a small hole (.075"-.100") hole in the center of the cap being careful to drill only
through the plastic and not the metal. Remove any loose plastic or metal, reinstall gas
cap.
WARNING: FAILURE TO DO SO MAY CAUSE AN EXCESS BUILD-UP OF PRESSURE IN
THE FUEL TANK, CAUSING A FAILURE OF THE NEEDLE AND SEAT. THIS COULD CAUSE
AN UNWARRANTED RELEASE OF GASOLINE, CREATING A FIRE HAZARD AND
POTENTIAL PERSONAL INJURY TO YOU OR OTHERS.
WARRANTY
Edelbrock Carburetors and all parts included on 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 any certification and
all warranties they may carry. Please contact Edelbrock with any questions.
The use of the words Harley-Davidson, various model names, designations, OEM part
numbers and the name K&N Filters are provided solely for reference and fitment
information only, there is no affiliation between Harley-Davidson, K&N Filters, S&S and
Edelbrock.

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