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Old 11-04-2011, 01:29 PM   #1
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Default 2006 KVF750 BruteForce Front Carb Problems

I have a customer's 2006 KVF750 BruteForce that is exhibiting problems with the front carb. Vehicle starts fines, but after running at part throttle for about 30 seconds it starts sputtering thru the front carb. The sputtering smoothes out, then about 1 minute or two later, it will sputter again. With the air box removed, you can physically see the diaphragm slide "bouncing" up & down during the sputtering bouts.

We've checked the valve clearances, checked the vacuum hoses from the intake tract to the fuel pump & regulator - they're fine. We've bypassed the fuel pump & ran fuel from an auxiliary fuel tank & monitored the vacuum from both ports simultaneously. Just before the diaphragm slide begins to bounce, you can see the vacuum (with gauges attached) for the front cylinder become erratic. It goes haywire as the slide begins to bounce. This symptom lasts for about 15-20 seconds and then smoothes out again.

If it sits and idles for a long time (until fully warmed up) you may get an occasional snort thru the front carb, but the problems shows up under part & full throttle conditions. We've had the carbs apart - cleaned, inspected and reinstalled them.

This is the 2nd owner. The 1st was a "little old man who only used it from his house to his mailbox and down to his boat dock for 2 years". The 1st owner claimed this behavior happened from day 1, but never concerned him. The current (2nd) owner said the condition has always been there, and hasn't ever gotten worse. He's just being concerned as he uses his BF for deer hunting and tends to go "way off the roads" and doesn't want to get stuck one day.

Any ideas, info or where to look for a resolution would be very helpful and very much appreciated.

Thanks
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Old 11-04-2011, 03:15 PM   #2
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Hey listen had the same problem with my bike, call me 3476722358 I'll walk you through everything, trust me
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Old 11-04-2011, 03:43 PM   #3
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Check the carb boots for cracks/perished. Also click on the link Welcome to Kawasaki.com and put in the vin# to search for recalls......seem to think I read on here that there was a recall on some 750 needles but cant remember what years were effected?
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Old 11-04-2011, 04:51 PM   #4
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Default carbs

Ya beat me to it.... Check the front needle - if its a NFKK - either put a #4 washer under the needle or order a new NFKL needle for the front carb.The rear needle is a NFKL. Check the carb boots for air leaks,check the front carbs diaphram on the carb slides plastic cover for miss installed diaphram or leaks in diaphram.I think thats about it.Sometimes those diaphrams can slightly fall out of their seat when you reinstall the slide and diaphram cover.
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Old 11-05-2011, 06:02 AM   #5
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If this condition goes away when the engine is warm , then it sounds to me like the classic symtom of an excessively lean idle . Both Kawie V twin's that I've owned , when cold , behaved like this when set to the "factory" carb calibration .

Usually , just opening up the PMS screw to 2 1/2 - 2 3/4 turns out makes a big improvement . If it's not totally cured , shim the needles .
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Old 11-05-2011, 10:49 PM   #6
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Hey madness mc, did our phone call work out
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Old 11-09-2011, 02:09 PM   #7
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Bump !!
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Old 11-09-2011, 02:40 PM   #8
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Quote: Originally Posted by phatjoe View Post
Hey madness mc, did our phone call work out
phatjoe -

I checked the Kawi site for the VIN & recalls - nothing outstanding.

I checked the needles and both are the NFKL needles recommended.

Any additional suggestions ???
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Old 11-10-2011, 04:15 AM   #9
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have you run a leak down test on it , a snort thru the carbs ,makes me want to think something is up with intake values, maybe need to be lapped, just a thought
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Old 11-11-2011, 02:48 PM   #10
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Leak-down test showed <5% for both cylinders, compression test shows ~70-75 psi both cylinders within 2-3 psi of each other.

It appears that it's running lean on the mid-range jets, as it's now idling fine (after a thorough cleaning and removing the air bleed restrictor valves from the diaphragms) and WOT operation appears OK.

Any additional thoughts ??
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