[How to install a K&N Powerkit] - ATV Riders Forums - Honda, Yamaha, Suzuki, Kawasaki, Polaris, CanAm, Arctic Cat, Kymco ATVs
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How to install a K&N Powerkit

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Posted by: Deathbringer

Let me start by saying that this is not the only way to do this, this is just to help someone who maybe gun shy on tearing apart their bike the first time. Also this tutorial makes no claims as to the accuracy of the information given.
If you goto the last page it has the WB's pipe movie link now added.


Posted by: Deathbringer

Step one...Turn off your gas, and remove the gas cap..I know it doesn't show that in the picture but you can't pull the plastic off without doing it.


Posted by: Deathbringer

Step Two


Posted by: Deathbringer

Step Three....You can now remove the black side panels...


Posted by: Deathbringer

Step Four... Notice the plastic hooks, you need to pull forward a little to remove the black side panel.


Posted by: Deathbringer

Step Five...Remove the screw holding the handle bar plastic on, this will make accessing the next two screws a ton easier.


Posted by: Deathbringer

Step Six.....after removing these screws the tank should just pull out.


Posted by: Deathbringer

Step Seven


Posted by: Deathbringer

Step Eight


Posted by: Deathbringer

Step Nine


Posted by: Deathbringer

Step Ten


Posted by: Deathbringer

Step Eleven


Posted by: Deathbringer

Step Twelve


Posted by: Deathbringer

Step Thirteen


Posted by: Deathbringer

Step Fourteen...this step seems to give people a lot of trouble..so get the right size screwdriver for the job... you will be hating life if you strip these out.


Posted by: Deathbringer

Step Fifteen


Posted by: Deathbringer

Step Sixteen, just drop it back into the hole that the old needle came out of...be carefull that the washer doesn't come off. Then reassemble the top before going onto the next step


Posted by: Deathbringer

Step Seventeen


Posted by: Deathbringer

Step Eighteen


Posted by: Deathbringer

Step Nineteen


Posted by: Deathbringer

Step Twenty.... You will need to turn the air/fuel screw all the way in and then back it out the amount of turns listed in the manual for your area..do this now because its a pain to adjust when its on the bike.


Posted by: Deathbringer

Step Twenty One.....After removing the stock jets use whatever is appropriate for your area, and reassemble the pieces.


Posted by: Deathbringer

Done..basically all you need to do is reassemble the whole bike and you are ready to go...
I didn't show the reinstall of the new filter but that seemed kind of obvious since you removed it earlier..
I hope some of you find this usefull and feel more confident in tearing apart your bike..
The project will take you about 1 1/2hrs, take your time and everything will go smooth.


Posted by: Deathbringer

You guys have any feedback..???


Posted by: yamaha1470

Thanks! This should go in the FAQ


Posted by: Punk13rym

in step #20 which one is the piolet jet. i coulden't find out which one it is. i just took my carb off and all of the gas came out how long will it take to start the engine with no gas in the carb? thanks


Posted by: Deathbringer

Once you put the bike back together and turn on the gas...give the throttle about 5 pumps,.it fired right up for us..
In step 20 the pilot jet isn't visible.... only the main jet which is the very top piece you see....

I have another part to this tutorial coming on the WB's E-Series Exhaust and you will get to download a .mpg of the first start up we did after mod'n the bike and you will see how easy it really starts and that is with the WB's rev box installed..


Posted by: EricB

good job dude, that will make it a lot easyer for people who have little experince with their bike.

is there any sort of advantage to removing the snorkle? i was thinking that i would take it apart and modify it but i've just been too lazy...and messing with this FL250 i have now. soon to have a atc 250r also, i hope!


Posted by: Deathbringer

Yeah you drop a wooping pound off the bike..LOL..
Seriously...we cut the snorkle right in front of the opening, then I found some really nice 3M foam to put in the end of it..we spray it black to blend in, it makes a great air scoop that way since it faces forward.. The only draw back to this would be if you spend a lot of time in water, which I don't..then you could suck it up easier...the idea Honda had was to allow the bike to pull air from a higher point to avoid pulling water into the airbox. The only other issue I have with it is that it passes very close to the engine, this to me could (no proof) warm the air coming into the box thus reducing HP. Anyway thanks for the feedback and hope it helps you out.


Posted by: EricB

yeah i totaly agree there about the intake. maybe i'll just have to trek it over to phoenix and go monkey with the snorkle now hehe.


Posted by: LilGuyOn400ex

that looks like alot of work.... all i did was take off all the plastic and took off the gas tank and just took off the carb all together and rejetted... it was alot easier then dismantling the front plastic lol


Posted by: TravEX

VERY informative,,,thanks


Posted by: pbarr86

Great info,

Besides the removal of the plastic (is different of course) is the actual carb work the same on a 300ex?

Thanks,
Paul


Posted by: Deathbringer

No clue dude..sorry.


Posted by: MX MadMann

well i take my carb off ALL THE TIME and i only use about hmm , well dang sure not as many steps as you did. heres what i do. take the left side panel off and take off the left gas tank rubber strap. take the hose clamps off both sides of the carb. grab the neck that goes from the airbox to the carb and bend it toward the left tire and hang it behind the little rubber thing that ur seat rides on. then unhook the gas line , AT THE FUEL SELECTOR VALVE. then pull the carb backwards to clear the engine boot. then , here comes the semi-hard part. lift up on the gas tank and at the same time , pull the carburator out the top and toward the shifter , make sure that the throttle cable goes underneath the fuel selector valve. and it will hang there on the side of your motor by the cable while you do what you need to do. this way , you can leave on most of ur plastic and ur gas tank and the airbox. that little thin piece of black material under the fuel selector i believe it is , chunk it. this is what i did a LONG time ago.


casey


Posted by: Doibugu2

There are always short cuts that you can take as you get better at things, or more knowledgable, but Deathbringer took the time to take pics and go step by step for us guys who have never taken our quad apart. Some of us need to taken everything apart before we can start taking shortcuts.


Posted by: MX MadMann

yeah thats true. ive been wrenchin on my 400 for about 2 years now and its gettin pretty simple. i started when im 16 years old now and i wish i could get a summer job at a honda shop or a motorcycle repair shop but oh well. im to much of a bum.


Posted by: Deathbringer

Yes there are alot of shortcuts...I know my one friend has done it without even pulling the carb off more then enough to twist it a little... he is also one of 3 people that have stripped screws and had other problems.. this as I stated..is only one way of doing it... If you want easy access, a clean way to work, and like to take you time to do it right the first time..especially if its your first "big" mod then this is how to do it. The way I did it only takes about 1 1/2 hours from beginning to end and that was with pictures so I don't think its that big of a waste of time..And yes there seems like more steps then there really is because of making pictures to show where things are at..
Nuf said enjoy.


Posted by: Punk13rym

but where is the piolet jet located is it behind the float boal or something. i don't know.


Posted by: Deathbringer

This should clear it up

http://www.exriders.com/jetting/jetting.shtml


Posted by: Deathbringer

Here is a link to the very first start up after mod'n this bike..we also added a WB's rev box, and a WB's pipe.

Sounds good I think
400ex small movie 400k


Posted by: Scott

The 300EX and 400EX carbs are NOT the same if I remember right. The cable for the 300EX comes right in throught the top of the carb and is connected to the slide (and needle), but the 400 throttle cable works the slide via linkage.

The overall procedure is basically the same for working on either carb, only difference is how and where the throttle cables attach.


Posted by: Deathbringer

Yeah I think you are right... the carbs are a little different, but the overall way of jetting should be close if not the same.


Posted by: RytM1

Death, is that the stock carb you were working on? I changed the main in my carb a few months back, and it didn't have the smaller round jet screwed into the end of it like the pic shows.


Posted by: Deathbringer

Yes it was a stock carb I was working on.


Posted by: Ex_Rider43

put this thread in the FAQ section it will be easier to see cuz that was on the 17th page of powertrain.


Posted by: EXevan91

quote:
Originally posted by Punk13rym
but where is the piolet jet located is it behind the float boal or
something. i don't know.


its under the lil plastic sheild under the main


Posted by: Nitro83

I have two rubber hoses that come off the carb. Where do they hook into???




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