I first want to thank Hayashi for the confidence to tackle my brute carb problems on my own Kawi shop wanted $59.00/hr to take the carbs off and run carb cleaner thru them. I have accomplished this task I have it back together and running I got the pops and backfires out of it but now it seems a little sluggish in the low end and doesn't seem to have the power it should, also it kinda labors when it idles, would this sound like a diaphram getting week cause when i looked at them one of them looked funky kinda wrinkled and thin. Thanks again any help will be nice

 

Hello,
Don't think I can help you, but you may be able to help me. Sounds like my Brute is doing what yours was. 2 months ago I could go from stop, full throttle and the wheelie nice and smooth. Now it goes sputter sputter, pop pop until enough rpm and takes off fine. Sat for 2 months. Hoping that I just need to get the carbs cleaned. If I can find out how to do this or you have any pointers, please let me know
Thanks

 

It all sounds like carburetion problem. either too lean or too rich.

Sandc - Maybe too lean. Air leak into air intake somewhere. While idling, spray carb cleaner and see if idle revs up. If so, there is a leak.

gohead - Maybe too rich. Check choke plunger for any sticking.

 

Hayashi
I will be pulling things apart tomorrow. thanks for reply, I will check the plunger. Just bought the download manual and will try to get carbs off to clean I suppose. Not sure what to do. I may just take them off and take down to a dealer to let them clean them up. I really don't want to mess anything up. Its a shame it was running so good before it sat for 2 months. Economy kinda has thins bogged down. BTW it will launch almost normal at ~3/4 choke if that clues anyone in. Also, where do you get a special tool for pilot screws?
Thanks

 

<div class="FTQUOTE"><begin quote>Originally posted by: gohead

I will be pulling things apart tomorrow. thanks for reply, I will check the plunger. Just bought the download manual and will try to get carbs off to clean I suppose. Not sure what to do. I may just take them off and take down to a dealer to let them clean them up. I really don't want to mess anything up. Its a shame it was running so good before it sat for 2 months. Economy kinda has thins bogged down. BTW it will launch almost normal at ~3/4 choke if that clues anyone in. Also, where do you get a special tool for pilot screws?
</end quote></div>

You don't need to remove carb set to check/clean plungers (2) - one for each carb.
They are located at LH side of carb set as you are sitting on the quad. Just remove the side cover plate on the carb set and there they are. Removing the fender/plastic pieces are more work than anything.
&gt; Remove Left side cover
&gt; Remove front fender.
&gt; Follow the choke cable which splits into two cables.
&gt; Remove the left side cover plate on the carb set.
&gt; Remove choke plunger from each carb.
&gt; DON'T lose the spring inside the plunger.
&gt; Inspect/clean out the cylinder inside where the plunger is goes up and down. Any corrosion/debris/fuel varnish will cause the plunger to stay (partially) open, allowing excess fuel to flow into carb and cause too rich condition.

The name "choke" is misleading on Kawi ATV because it is not really "choking" which is reducing the air supply. But on Kawi ATV, it is acutally a fuel enrichening system which supplies excess fuel to increase the f/a ratio. If the plunger is sticking/partially open, the carb is getting excess fuel via the choke/plunger fuel circuit. Also, sticking choke plunger causes, of course, plug fouling - especially the front one.

See the choke plungers below, all cleaned out and ready to go back in.

 

Thanks foe the reply. I went ahead this morning and pulld the carb off. Cleaned everything I could find to clean inc. plungers, jets, diaphragms, etc. Found that the kawi boys had the pilot screws at 5 1/4 an 4 4/8 turns out. Said to self, what the hey put them at 2 1/4. Put it all back together and it runs fine. Not sure where the prob was, but seems fixed. The jet strainer thingys were a little corroded and I ran wire through them and flushed them thoroughly. Oh well got to say it was a royal PIA but I do believe if done again it would go much faster after the initial learning curve
Thanks again

 

Good to hear the problem is fixed.
Perseverance pays off!

<div class="FTQUOTE"><begin quote>Originally posted by: gohead
Found that the kawi boys had the pilot screws at 5 1/4 an 4 4/8 turns out.
</end quote></div>

Like I worte earlier, it sounded too rich. Someone must have jacked up the pilot screws instead of properly cleaining the choke plungers/carbs in an attmept to correct the poor running problem at low rpm range. Almost all the time, the pilot jets/circuits beocme problematic first (due to their smaller fuel passage). Next time if your quad would be sat for more than a week, mix in some fuel stabilizer in the fuel tank to retard the carb gumming. And run/ride the quad for minimum 5 minutes after mixing so that treated fuel can fully flush the entire fuel delivery system.

 

where are these pilot screws you are talking about I would like to check mine