BannedCR500Riders.com

Well, I'm kinda in the poorhouse right now and I need a new carb for my '85, left it sitting in a moist basement and the slide stuck big time.
I was all set to buy the cheapest PJ I could find on fleabay when I took a stroll to the basement to see what I could get into.
There it was, sitting right where I put it probably 3 years ago.
Turns out it's a 38mm PWK from a '93 Kawasaki KDX250 parts bike I got a long time ago.
What friggin luck!
Shit, I needed something to go right for me about now!

Can anybody give me some guidance on jetting and slide numbers for the 38 PWK?
I might be riding this friggin thing before too long!

Taking it apart I find the choke broken inside the carb body.
It's available just waiting to see what slide number and jets I need.
Here's what it has,
main 165
throttle cutaway 5
slow jet 42
jet needle r1368h

Hopefully some of that is compatible with what I need.

Whats your elevation? Average humidity?
Your 1368 is a CGJ. 168 seems lean for the C series.
168 would be good for D series needle.
42 pilot is a good starting point.
5 cutaway is richer than 6 and effects are 1/8 to 1/4 throttle range.
It should run just be careful if you run that 168 main and are at lower elevations.
Ported bike I run with a CGJ needle was so rich it just coughed at 3500 ft and above.

I'm at 1250 elevation, my '85 bike is ported also.
My manual calls for a R1368N needle, 86-89 are all different.
I'm hoping the main and slow jets will just transfer from the PJ.

I would recommend a 175 main jet to be safe starting point.
I'm pretty sure that 165 could be to lean for that C series needle.
The C needle doesn't taper off to the tip as quickly as a D needle does hence the need for a larger main jet. Cheap $10 fix to prevent a melt down.

48-52
DGJ or 1468
172-175

These things usually love the D/14 needle.

Here's what the PJ has.
main 172
slow 60

I'm assuming someone jetted this bike so I'm hoping they should just transfer over.
The reason I'm assuming is, someone spent the money on an Ohlins shock and possibly did the front.
Also, the cylinder was ported and the head modded, and the pipe was reshaped by a known race shop.
I know it's a big assumption.
The way I see it, I need to get a jet needle and 6 slide?

You pilot is way to rich you gonna need mid 40s pilot

Damn, I know I'm not the sharpest knife in the drawer but this jet needle conversion crap is confusing.
I think I got it though.
if I am correct, my jet needle on the PWK right now is CHJ or R1368H.
I was reading the chart left to right and it should be read, left-right-middle.

Somebody school me if it's wrong.

The manual calls for 168 main and 65 pilot for '85.
Honda is known for rich jetting from the factory.
Right now I have 65 and 42 pilot jets and 165 and 172 main jets available.

Here is the baseline setting difference between the PJ and PWK. PWK settings are at the bottom of this info. Your 5.5 slide is richer, which will help with the 42 pilot. Likely start with air screw only 0.5 turn out to get a richer mixture.

Here are some base line settings for water cooled bikes. These are from the Honda Service manual, 85-91, and 92-01:
Needle and position: Main Jet:
'85 - R1368N 3rd '85 - 168
'86 - R1372N 4th '86 - 172
'87,'88 - R1370N 4th '87 - 168
'89 - R1370NS 3rd '88 - 175
'90 - R1369NS 3rd '89-'01 -170
'91-'01 - R1368NS 4th

Pilot/Slow Jet: Air Screw:
'85 - 65 '85-'88 - 1.5 turns out
'86 - 60 '89-'90 - 2.0 turns out
'87,'88 - 58 '91-'01 - 1.5 turns out
'89-'01 - 55

As as I know all the PJ carbs are 6.5 slides.


Float level for all years is 16mm
Carb ID numbers:
'85 - PJ21A '92 - PJ27J
'86 - PJ24A '93 - PJ27L
'87 - PJ27A '94 - PJ27M
'88 - PJ27B '95 - PJ27N
'89 - PJ27C '96-'01 PJ27P
'90 - PJ27E
'91 - PJ27H

Base line for Service Honda CR500AF with 38 and 39 PWK.
Main - 175
Pilot - 55
Needle - 1368N 3rd clip position
Slide - 6.0
AS - 1.5 turns