Section04ENGINE
Subsection 07 (CARBURETOR AND THROTTLE CABLE)
MODELS
THROTTLE
SLIDE HEIGHT
(drill bit size)
± 0.1 mm (± .004 in)
GSX 500 ss Sport
MX Z 500 ss Trail
MX Z 500 ss R
Adrenaline/Trail
1.5 (.059)
GSX 600 R Sport
MX Z 600 Trail
MX Z 600 R Adrenaline/
Renegade/
Renegade X/Trail/X
1.6 (0.063)
Summit 600 R
Adrenaline/X
2.0 (.079)
GSX 800 R Limited
MX Z 800 R Adrenaline/
Renegade/
Renegade X/X
1.7 (0.067)
Summit 800 Sport
Summit 800 R
Adrenaline/HM/HM
X/HMXtrem/Sport/X
2.0 (.079)
INSTALLATION
CAUTION: Never allow throttle slide(s) to snap
shut.
Install dual carburetor assembly.
Make sure dual carburetor assembly is prop-
erly inserted into carburetor sockets, hold it in
place and tighten retaining clamps.
Secure heated carburetor inlet and outlet
lines with clamps, tighten to 1.5 to 2.0 N•m
(13to18lbf•in) and remove pincher on outlet
line.
Allow coolant to flow from coolant tank to carbu-
retor before opening valve.
Connect all hoses to dual carburetor assembly and
to DPM, making sure there are no kinked hoses
after reconnection.
Throttle Cable Adjustment
To adjust throttle cable, refer to THROTTLE CA-
BLE at the end of this section.
Choke Cable Adjustment
Adjust choke cable as per following procedure:
Loosen choke cable housing adjusting and locking
nuts.
Connect choke cable on starter lever no. 4.
While choke lever is fully open, pull choke cable
until starter lever reaches the stopper. Tighten ca-
ble housing adjusting and locking nuts in this po-
sition.
As a confirmation, the gap between the stopper
and the bracket should be within 0 and 0.5 mm (0
and1/64in).
A
A32C32A
A. Within 0 and 0.5 mm (0 and 1/64 in)
Reinstall air silencer and DPM.
Reconnect DPM air vent hose at air silencer.
Make sure dual carburetor assembly properly
slides into air silencer adapters; hold it in place
and tighten clamps.
Reconnect DPM air vent hose nipple to air si-
lencer.
Reconnect air temperature sensor connector to air
silencer.
Idle Speed Final Adjustment
CAUTION: Before starting engine for the
final
idle adjustment, make sure that oil pump is
adjusted. The oil injection pump adjustment
must be checked after each time carburetor idle
is adjusted. Refer to OIL INJECTION SYSTEM.
mmr2004-Rev 151
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