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View Full Version : How to install a K&N Powerkit



Deathbringer
06-29-2002, 10:45 AM
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.

Deathbringer
06-29-2002, 10:46 AM
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.

Deathbringer
06-29-2002, 10:47 AM
Step Two

Deathbringer
06-29-2002, 10:48 AM
Step Three....You can now remove the black side panels...

Deathbringer
06-29-2002, 10:48 AM
Step Four... Notice the plastic hooks, you need to pull forward a little to remove the black side panel.

Deathbringer
06-29-2002, 10:49 AM
Step Five...Remove the screw holding the handle bar plastic on, this will make accessing the next two screws a ton easier.

Deathbringer
06-29-2002, 10:49 AM
Step Six.....after removing these screws the tank should just pull out.

Deathbringer
06-29-2002, 10:50 AM
Step Seven

Deathbringer
06-29-2002, 10:51 AM
Step Eight

Deathbringer
06-29-2002, 10:51 AM
Step Nine

Deathbringer
06-29-2002, 10:52 AM
Step Ten

Deathbringer
06-29-2002, 10:53 AM
Step Eleven

Deathbringer
06-29-2002, 10:53 AM
Step Twelve

Deathbringer
06-29-2002, 10:54 AM
Step Thirteen

Deathbringer
06-29-2002, 10:54 AM
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.

Deathbringer
06-29-2002, 10:55 AM
Step Fifteen

Deathbringer
06-29-2002, 10:56 AM
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

Deathbringer
06-29-2002, 10:56 AM
Step Seventeen

Deathbringer
06-29-2002, 10:57 AM
Step Eighteen

Deathbringer
06-29-2002, 10:57 AM
Step Nineteen

Deathbringer
06-29-2002, 10:58 AM
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.

Deathbringer
06-29-2002, 10:59 AM
Step Twenty One.....After removing the stock jets use whatever is appropriate for your area, and reassemble the pieces.

Deathbringer
06-29-2002, 10:59 AM
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.

Deathbringer
07-01-2002, 01:18 AM
You guys have any feedback..???

yamaha1470
07-01-2002, 05:15 AM
Thanks! This should go in the FAQ

Punk13rym
07-01-2002, 07:31 AM
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

Deathbringer
07-01-2002, 09:05 AM
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..

EricB
07-01-2002, 04:52 PM
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!

Deathbringer
07-01-2002, 05:00 PM
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.

EricB
07-01-2002, 06:15 PM
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.

LilGuyOn400ex
07-01-2002, 09:17 PM
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

TravEX
07-01-2002, 09:20 PM
VERY informative,,,thanks

pbarr86
07-01-2002, 09:33 PM
Great info,

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

Thanks,
Paul

Deathbringer
07-01-2002, 10:01 PM
No clue dude..sorry.

MX MadMann
07-02-2002, 02:41 PM
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

Doibugu2
07-02-2002, 03:02 PM
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.

MX MadMann
07-02-2002, 03:17 PM
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.

Deathbringer
07-02-2002, 04:42 PM
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.

Punk13rym
07-02-2002, 06:01 PM
but where is the piolet jet located is it behind the float boal or something. i don't know.

Deathbringer
07-02-2002, 06:57 PM
This should clear it up

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

Deathbringer
07-07-2002, 11:41 PM
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 (http://webpages.charter.net/400ex/images/400ex.MPG)

Scott
07-08-2002, 06:50 AM
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.

Deathbringer
07-24-2002, 10:48 AM
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.

RytM1
07-24-2002, 12:17 PM
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.

Deathbringer
07-24-2002, 12:32 PM
Yes it was a stock carb I was working on.

Ex_Rider43
08-12-2002, 02:36 PM
put this thread in the FAQ section it will be easier to see cuz that was on the 17th page of powertrain.