Kawi2strokes.com Forum

FDM=VITON=Factory Directed Modification(thanx Dave)

It's been a long 4 weeks waiting for powder coating. 2 weeks over original estimate is not bad when doing restorations though. Blasting parts for coating is difficult in high heat and humidity. It was sad dropping the frame and other assorted parts off and seeing it put on the list behind other bike frames, radiators, and fencing. Coating shop did a great job, and I am grateful for his hard work.
Today was a good day picking up the freshly done parts. I have wrapped the frame tubes with foam insulation to keep it safe for now, as this is being built in my friends busy automotive shop. Space is always at a premium, but it is much nicer working there with his array of tools than in my all too small and hot garage.
Hope you all have a Happy 4th of July.

Yes, that is the first part of it, the FDM (Factory Directed Modification), end cap O ring crush depth.

The other part of the oiling system tech is the relief pressure, measured in air pressure, through the check valve. MOST check valves release somewhere down from what they should, 2.5 to 3.1 PSI of AIR only. Measure with a hand held and actuated low pressure pump, banjo bolt, nut and washers through the oil line at the oil pump end fitting on the line, GENTLY pump the line up, and LISTEN to the valve, you will hear when the valve reaches its "blow level".

I have not used anything past stock parts, but there are others here, and KTOG that have gone far enough to modify stuff to work. All I ever did was to gently stretch the stock spring, to get the valve to blow off at 4.6 PSI, which is what the factory engineers for both Kawasaki and Mikuni specified. 4.60 PSI of AIR pressure.

We came up with both these procedures when there were problems of over oiling, and also, modified the oil pump baile (the wheel the cable attaches to). Stock, the wheels were adjusted way too rich. We modified the cable holder on the baile to allow the LAST DOT on the pump to align with the line on the side post at FULL THROTTLE, no richer. Look at the baile, and the one post with the line, full throttle, last dot to the line, correct. OF COURSE, THIS SETTING IS DONE AFTER GETTING THE IDLE, AND CABLE SET, AND THE CARBS BALANCED, WIT THE ENGINE OFF, OFF, OFF.

Oil pump eccentric is designed to reach 20:1 fuel to oil ratio at the last dot to line, and at idle, 100:1 fuel to oil ratio.

I never did get explanations as to just why a brand new motorcycle had the timing and pickup gaps incorrect, float levels too high, carbs not balanced, and oil pumps not adjusted correctly, with too low a blow off pressure for the oil limes, one would figure it would have been done correctly right out of the factory, from Mikuni, and/or Kawasaki.

Hope this helps.

I had never seen the abbreviation FDM before. Thanks H2RTuner for the detailed explanation. I have been following the Service bulletin, http://kawatriple.com/bulletins.htm#Bul ... 073%20H-16 along with tips like yours. I am curious about your opinion on the Note from Dave Ray regarding milling .80-1.00mm to the early end caps to get similar results in the above link.
It has been extremely convenient for me to have a service station owner as a friend, as he lets me work on the bike in his shop and utilize all his test equipment so that I have not needed to purchase anything.
As far as your comment about setting gaps and float levels, I would expect things like that considering what they go through during shipping. I get a cheap thrill getting everything adjusted to spec, but then again I find things more fun when I don't have to do it every day for a living. Last thing I want to do in my own house is electrical work after doing it all day at work.

I suspect he'll agree with Dave Ray's note.

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If it surges, that's normal, upshift.

I was one of two tuners for Yvon DuHamel at Team Kawasaki Road Race USA, in the early 1970's. The other was/is my pal, Steve Whitelock

The FDM says the crush was reduced down from 18.xx mms, to 16.xx mms. so, cutting the face of the end cap does the same on the early caps to increase the O ring crush.

And, Jim is right, I do agree with myself, I am David Ray.

Now I know. That put quite an embarrassing smile on my face.
Thanks Dave.

There's nothing to be embarrassed about, and now you know. : )

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If it surges, that's normal, upshift.

I completely agree, nothing to be embarrassed about at all, sir.

All well done, boys.

I was not reading well enough the FDM thing and I assumed it was the o-ring material.
For what it's worth FDM is Viton(brand) of rubber material.

And the Factory Directed Modifications issued for know oopps from mother Kaw.

cliff

ps

Maybe a normal 4th this year? Enjoy!