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Discussion Starter #1
I decided that Orleans and I were moving too quickly, so I slowed it down. Pulled the radiator (whcih apparently had a previously unknown leak), pulled the carbs (which meant pulling everything I'd busted knuckles on), and broke down the carbs to make sure everything was in working order. All is mostly ok. However, in reinstalling the bracket on the starter plungers, I appear to have an extra plastic washer. And while the spring-loaded side (front carb) is operating smoothly, the rear carb plunger is cranky. Clymers wasn't much help.

Can anyone help me sort out the installation order on the rear? I've got the rod in the bracket, bracket's on the plunger, and the bracket is installed on teh carb via a phillips screw, metal washer, and then a small locking washer, and then there's the screw head. That's it. And then there's this little extra thing. Aside from extra parts, do the starter plungers differ between front and rear carbs, or are they interchangeable?

Thanks!!
 

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and the Adventure Cycle
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Is THIS pic (from Ron Ayers) any help?
I would think front & back are the same, just pointing in different directions.
 

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Discussion Starter #3
Thanks, Hyper - I went back and looked at that last night, but not after I had put everything back together. It doesn't look like I missed anything, and that the plungers should be operating normally. Just can't see where this extra plastic washer might've come from; or why the rear plunger is sticking. Always possible (in re: the washer) that the previous owner jury-rigged something, and did it wrong.

Hmmmmm....:confused:
 

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and the Adventure Cycle
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Wish I could be of more help here, Cindy.
I've had very limited experience with carbs. I gotta give ya credit for gettin' in there and tryin' to get them workin' right !
Two thumbs up and a toast for good luck to ya !! :smiley_th :beerchug: :smiley_th
 

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Thanks, Hyper - I went back and looked at that last night, but not after I had put everything back together. It doesn't look like I missed anything, and that the plungers should be operating normally. Just can't see where this extra plastic washer might've come from; or why the rear plunger is sticking. Always possible (in re: the washer) that the previous owner jury-rigged something, and did it wrong.

Hmmmmm....:confused:
Cindy -

The front and rear are interchangeable. If you go to RA and to carb parts, each item listed shows as quantity 2.

The shop manual states that if the starter plunger does not move easily and return when spring tension is applied, to replace the carbs. This leads me to believe that something would have to be bent, scored, or otherwise damaged that is not repairable, according to Kaw manual.

I would take the carbs off, and make sure that they operate normally sitting on your bench. If not, try switching the components from one carb to another and see if the problem follows you. Then one of the components is bad. If the problem stays with the original carb, then there is a problem in the carb housing, that would require a new housing.

If they work right on the bench and then you install the carbs and it s a problem, then look at your linkage as something is binding.

My money is on something binding externally.

Let us know.

Jon
 

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Discussion Starter #6
Hmm..maybe I'm looking for a problem where there isn't one. The front carb - the spring-loaded one - works absolutely fine. And when I move that one, the rear starter plunger moves up and down ok. I was just yanking on the rear bracket and the plunger was coming up....holding there...and I'd have to manually put it down. But since the mechanism should (in my world of how-motorcycles-work theory) operate off the spring-loaded side, maybe it's ok?

Of course, I'm gonna say that because disassembly means putting that (&*@#%[email protected]#%+)* spring back on. (Yeah, it was that much fun!!) :wow:
 
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