Frank Angerano

@Flipper Tiffany Roper Jones How’s it going? Did you locate and order a stator ?

I would hold off until you have it running and see what happens. If that thing sat it could be just a matter of getting things moving in the gearbox.

Any luck ?

You could double check that the float is set properly as well making sure your not set to high.

That could be happening but what I’m referring to is the needle in the carb on the throttle. See the pic. The lower you move the clip the more fuel it allows.

Have you checked the needle on the throttle slide to see what clip it’s on? I would try to move the clip down one or two spots closer to the bottom. And when the engine is running if you can turn the air /fuel screw all the way in the engine should shut down. If not then that screw is worn and needs replacement. The engine should immediately respond to any adjustments on that screw. If not then it’s def going to need a new jet kit. I was looking on eBay and Amazon. It has to be an oem or better brand. It was $27 bucks. It has to have the air fuel screw as well and all jets. I would order one and take the carb completely apart and soak it in a good bath for a day or two. Then blow every port out on that cab with some good air pressure. Reassemble and set the air/fuel screw at 2 full turns from a snug position. That would be my way to go about it.

You will do just fine. Mine took me a week to do. A little each day. Let me know how the jets work out.

The main is the one with the needle. It gets the larger of the two jets. They have numbers on them. Mine were not legible due to being what looks to be worn or sanded maybe during the cleaning process of the previous owner. So if you can read the numbers then lol at the carburetor section of your manual and it clearly explains where they go. But for sure the larger hole jet is at the needle location. Yes all can spray. Wire wheel in a drill and sand paper. I spray a good prep coat on before and spray away! The prep coat is a clear type coat that helps the new paint stick well. And FYI all of this material I bought on line for $125 bucks. That includes the new color matching chain and I was missing the air factory box. That air box assembly was $45 so really it cost me $80 if I wasn’t missing that air box. That chain was only $20 bucks.

Here are a few pics of the work I did. The color I found on eBay and Amazon. PJ1 Color Matched Frame Paint 99-02 Kawasaki Green 12 oz. https://www.amazon.com/dp/B00230IC3M/ref=cm_sw_r_cp_api_i_UO6DDbBDAQ4ZW The other colors are standard gloss black for nerf bars and then high heat satin finish on the exhaust. The aluminum portion (silencer) I used an aluminum polish called mother’s. It’s great for all soft metals. Mothers 05101 Mag & Aluminum Polish - 10 oz https://www.amazon.com/dp/B0009H519Y/ref=cm_sw_r_cp_api_i_GT6DDb4RMNXGF

Let me know if you need the paint color. I found an oem dead on match. How did the carburetor work out ?

The one with the larger hole goes on the main.

Double check and don’t make the same mistake I made. Make sure you put the right jets back in the right spot. When putting the carb back together the pilot jet and the main jets are the same thread. I reversed them and the bike died at as soon as I put it in gear.

Ok figured the blue and brown wires. They are for your rear brake light. One is by the carburetor should run to a brake switch on the rear brake petal. The second set up by the front goes to the right brake handle lever.

Have you jumped the fan to see if it runs ? If so the second test would be to remove the sensor from the radiator and connect a tester to both leads of the sensor and put the tester on continuity. There should be no reading while it’s cool. Then put it in a small pot of water (just the sensor part) and as the water heats up the sensor should close giving you a reading. It should close at about 185-190 deg.

Maybe extra lighting at best because this bike has no battery. It’s self reliant as far as power goes so you really couldn’t add much more onto it.

Yes I agree, it’s for an accessory add on maybe. I will look at my own bike this afternoon to verify. But that was my take as well.

Good luck, keep us posted.

The fan sensor, the wires all in tact ? The blue wires that I see as per the diagram are a 12v positive. The browns I’m not really seeing except for the stator wires. Double check that it’s not a brown with a stripe on it. Meantime put a tester on the blue wires and see if the test for 12v positive.

That would be the fan sensor. Jump them and the fan should come on. But the bike needs to be running obviously. As far as the other two I’m going to take a look now.

The sensor should be lower right side of the radiator if your sitting on the bike. As far as ignition switch is it an oem switch ?

The wires going to the fan and the sensor are circled. Test them as I indicated and see if the fan comes on. Meantime send me a pic of the wires and the area that they are located in I will see where they go on my machine.

So you got spark!! That’s great!!!! The cooling system fan will only work when the engine temp gets to its set point. On the right side of the bike the radiator bottom should have a sensor on it. There should be two wires connected to it. Take them two wires off of the sensor. When the engine is running use a jumper wire and jump the two wires. That fan should come on, if so that’s good news as far as the fan working and the power going to it. The only thing next is to see if the sensor is working. My guess is it’s working fine. My bike took a while to heat up and come on. If in doubt swap it out for a new one. I will get back to you with the wire colors for that fan and the wires your talking about that are loose.

What kind of weird noise? And smoke coming from the exhaust is mostly a valve cover leaking. Unless your valve seals are bad but you would get a lot of blue smoke from the exhaust. How far was it out of time because if it was far out then then the piston and valves could have kissed causing a bent valve condition.

Sh** happens. Look in the download section I’m sure there is one there.

Very nice! What size bike is she riding now ? That rim if you heat it up and take a small sledge hammer/lump hammer wrap it in duct tape and slowly hit it back into shape. Take your time.