Carb Synch confusion

[chicagorandy]

Yes, me the newbie PIA again - lol

My local Kawasaki dealer quoted $135 to balance and synch the carbs, I took the 'false bravado' route and instead ordered a $77 Emgo carb synch tool (4 gauges).

Now for my confusion.... the service manual (at 2-9) says attach the synch tool fittings and hoses and re-install the airbox and filter, start the engine, note any variances and then synch the carbs.

How the heck do you manipulate the carb adjustment screws with the airbox in place? Are they not under the airbox?

Wuzzup wit dat?

[chevyman1]

I leave the air box off, sync the 2 right then the 2 left cylinders first then sync the right to the left.
The sync tool with the 4 gauges is not vary accurate because you are using 4 different gauges.
you don't know if the gauges are reading all the same.
the best one to use is a mercury unit ,hard to get these days .
This is what I use
http://www.ebay.com/itm/Race-Pro-Mercur ... 18&vxp=mtr
Motion Pro makes one that's similar without the mercury
http://www.motionpro.com/motorcycle/art ... 11__99_90/

[chicagorandy]

Leaving the airbox off makes perfect sense to me.

The 4-gauge balancer is already on order. I reckon I can always verify the accuracy by testing the same carb using each gauge one at a time before I start the balance dance.

As it stands right now I have 5 or 6 separate orders for Voyager 'stuff' out there in the interwebs - everything thing from missing fairing screws, to a new trunk light and switch, to a cup holder, to a digital volt gauge, to the quite pricey igniter and of course this balancer. Never said new bike ownership was gonna be 'cheap'.

One redeeming factor is I am 65, semi-retired and live alone and don't have to try and explain this to anyone - lol - my two remaining children already know that being of sound mind I'm going to the grave as close to penniless as I can - lol

[Bill O]

Leaving the airbox off makes perfect sense to me.

The 4-gauge balancer is already on order. I reckon I can always verify the accuracy by testing the same carb using each gauge one at a time before I start the balance dance.

As it stands right now I have 5 or 6 separate orders for Voyager 'stuff' out there in the interwebs - everything thing from missing fairing screws, to a new trunk light and switch, to a cup holder, to a digital volt gauge, to the quite pricey igniter and of course this balancer. Never said new bike ownership was gonna be 'cheap'.

One redeeming factor is I am 65, semi-retired and live alone and don't have to try and explain this to anyone - lol - my two remaining children already know that being of sound mind I'm going to the grave as close to penniless as I can - lol

I would suggest that all new Voyager 1200 owners not hesitate to post parts needs on the forum. Many, many off us have been hoarding parts for some time, and can possibly ease your pains for a lot less than what the on-line suppliers are desiring. I understand that we need to support the suppliers, but sometimes the on-line suppliers are not supporting us with the exorbitantly high prices.


Bill O

[Littlebeaver]

I would check each gauge before I started... Just to confirm they all read the same..

[voyager55]

http://www.carbtune.com Website has easy to follow instructions
Best & most accurate, easy carb tool I have ever used. Vacuum gauges bounce all over the place. Hard to get a accurate adjustment
Hook up to all 4 carbs
You sync carb 1 & 2 first, then carbs 3 & 4 Then the middle adjustment screw syncs both sides together.
You must remove the air cleaner housing to get at all the adjusting screws
Take your time, get them all adjusted properly

[ekap1200]

Yes, me the newbie PIA again - lol

My local Kawasaki dealer quoted $135 to balance and synch the carbs, I took the 'false bravado' route and instead ordered a $77 Emgo carb synch tool (4 gauges).

Now for my confusion.... the service manual (at 2-9) says attach the synch tool fittings and hoses and re-install the airbox and filter, start the engine, note any variances and then synch the carbs.
How the heck do you manipulate the carb adjustment screws with the airbox in place? Are they not under the airbox?

Wuzzup wit dat?

A common tool years ago when cars were carbed was a air-screw adjustment tool. Which was a steel tube bent at either 45 or 90 degrees ( depending on the tool manufacturer ) The 90 degree one will work on our bikes. And with a tubing bender the 45deg. can be bent to fit. It had a flexible cable with a knob at one end and a 1/4 drive at the bent end. The tool is about 16 inch's long. I have one that was from ( MAC TOOLS ) and all that I need do is to attach my vac gauge's , and with the bike warmed up and a very large fan in front of the bike , sync the carb's and call it a day. I don't remove anything but whats on the vac ports.
Ask some of your friends that are in the auto repair field if you can borrow one or shop around and purchase one. As a lifelong mechanic, I never removed more than needed to do any job. As for the calibration of the four gauges, do check them with a common vac port setup, some of the less expensive gauges may be a bit off. Gene Kap.

[ghostler]

On the 'net I heard of the feeler gauge method as an alternative to the expensive set of gauges. Has anyone tried that method on the XII? Does it work?

[chicagorandy]

I used to adjust the throttle cables on my Ural (so that both carbs were opening at the same time) by adjusting where they attach to the carbs - I suppose a feeler gauge could have been used for that chore?

But I still then needed to use my TwinMax to balance the carbs.

[doug of so fla]

When you sync the carbs you do not have to turn the screw but just a hair to make a big difference. Also the air screw on the bottom of the bowls of the carbs need to be set right. They have been plugged by the factory with a piece of lead and are not easy to do unless PO has removed the plugs. Do not touch throttle when adjusting carbs, must be idling good before you start, set idle with idle adjuster knob on left before you hook up sync tool. Doing carb's on a XII is not for everyone. If you want some good advice: contact Carl Leo, He can help you out before you get in to much trouble..

[voyager55]

Doug is correct. Also Put as little pressure as possible on the adjustment screws to. If you don't, you'll get a false reading. Remember to "Blip" the throttle every so often to.
Carb sync is very easy on our bikes. Just take your time & you'll save a lot of money doing it yourself. If i can do it, anyone can. I'm no mechanic either!
Once you complete it, you'll say "Boy! That was simple!"
And our bikes hold the carb sync for a long time to.
I just check mine every spring, but seldom do they need adjustment

http://www.youtube.com/watch?v=CYgN2-96Ik0

[HarryL]

When I syncronized my carbs on my 03 Voyager, I made a homemade tubing balancer similar to this one: http://www.650ccnd.com/mano.htm
I used automatic transmission fluid which was a good thing since my carbs were so out of balance and the levels were bouncing so bad that I pulled some of the oil into the carb before I could shut it down. a couple of blips on the throttle cleared it out.
I was able to use it when I put a pair of adjustable flat jaw vise grips at the bottom to crimp the hose to slow the pulses down without closing the flow off completely.

Harry

[gery]

You can synchronize your carburetors without taking off the air box if you have an angled screwdriver. But, with the air box removed you will do it much better and more accurately.

PS. I am using Carbtune gauge, I can recommend a very accurate measure.

gery

[EZdriver]

You don't need four gauges. I used my Rotax two gauge system. There are three balancing screws, all on the linkage, one between one and two, another between three and four, and a third between two and three.
You are simply opening/closing the butterflies between the two carbs to get the pneumatics balanced. Leave the airbox off, put your gauges on 1and 2, plug the other two ports. Balance 1 to 2. Now plug 1 and 2, and balance 3 and 4. The screws are between the carbs. Now plug 2 and 3. Put your guages on 1 and 4. Use the center screw to balance them. Done.

[chicagorandy]

I must confess that I verifed the carb balance using my TwinMax balancer. It has two hoses and a super sensitive analog meter.