Yes, those should be the correct #'s to get your bike finished.

 

just got the carb holder yesterday and unfortunately there is still a problem, now it will fit the carb but will not fit on the cylinder head, so i guess the cylinder head for both the carb and FI version are different, looks like its back to square one

here's a picture of both the carb holder : http://picpaste.com/carb_holder-6Qr7cWue.jpg

 

Gotta be a way to make it work...without buying a different head.

 

Check the parts fiche to see if the FI head is different.

 

Can you post the p/n that is stamped on your original manifold. I can't make out the # in the pic. It would really surprise me if they redesigned the head just for F/I apps.

 

Yeah, im really surprised myself that they redesigned the cylinder head but maybe the carb models are not manufactured in Thailand and they use different die cast to mould the head in Thailand which probably uses a new mould design.

The part number of the original manifold (the kawasaki packing calls it Holder-Carburetor) is 16065-0045. I checked and found out that almost all part number 16065-XXX is used as the carb holder on different models. The centre to centre hole distance is 60mm for the carb model and 75mm for the FI model.

I was at the workshop earlier and the mechanic found a probable solution to the problem, we decided to cut the 16065-1283 into half and discard the part where it mounts to the cylinder head and we slotted the remaining piece into the 16045-0045, it has a nice tight fit and the mikuni can be slotted in nicely. They plan to put super glue around the outer part of the remaining piece of 16065-1283 before slotting it in.

Do you think this method is safe if it works? I mean, any possibility the super glue might not be strong enough to hold? Is the pressure of fuel from the carb to the cylinder very high?

Anyway they will let me know on Monday if it works, still unsure if the carb will fit in nicely after plugging in the manifold to the airbox since this method will cause the manifold to protrude out a bit. I shall update on Monday.

 

To use the rubber piece as a spacer I would want to seal the two together with a good quality RTV sealant. I would think that superglue would be brittle and crack when the clamp is tightened down to secure the carb, and that might cause some air leaks.

 

There must be some ex-pat NASCAR tech guy working for Kawasaki-it looks like they designed a restrictor plate fro the FI models compared to the carb'd versions. Glad your tech was able to Rube Goldberg it back together-just pay close attention to the integrity of the seal and ride the snot outta it.

 

hi all, thanks a lot for your feedback which were very useful for me to finally get the bike started. the method which was mentioned the other day worked without any fitting problems. However i faced one more problem which i hope will the the last of my problems. When fitting the IMS Tank, the bike seems to be missing some parts to connect the fuel tank to the carb, since the bike is originally FI model, i need confirmation on the additional parts i need to purchase. Below are the list of parts and the part numbers, can someone confirm are those the only part i need?

1) 49019-1057 (Fuel Filter Res)
2) 49019-1077 (Fuel Filter On)
3) 92055-1386 (O Ring ID=9.5)
4) 92055-1387 (O Ring ID=11.5)
5) 51023-1322 (Tap Assy, Fuel)

Cant wait to ride the transformed bike

 

Regarding after market intake manifolds, I measured the intake in my 2007 D-Tracker (made in Thailand) recently and it appears that the neck on it is angled with the front to back distance measured at the top maybe 3 mm different IIRC than the front to back distance at the bottom. Plus the bolt spread is something like 62-63mm which is not something Mikuni/Sudco etc offers.

Though you might get away with elongating the mounting holes