Installing a 39 mm PWK carburetor on a Honda Pilot By hoser..
The First thing you need to do is drain the radiator before removing the old carburetor, the stock carburetor has a water jacket that runs through it to keep the carburetor warm in cold weather to reduce the chances of the slide sticking, you can plug the small coolant hoses because you will not be using them with the new carb. Once you get the old carburetor off you will probably notice that you can not remove the throttle cable without taking a file and and gently file the top off the old carburetor or drill two small holes in the side of the cap where the snap ring is, press from both sides while pulling the cable out. Two, cut the cable flush with the brass, then drill straight down when it hits the ring it will typically pop out (you will need to buy a new cable). I think its a 5/16 bit but don't quote me on that, you can start small and work up till it comes out. See this on removing the cable from your carb top. I don't really know why Honda made it so if you need to destroy the top of the carburetor or have to destroy the throttle cable. When you file the old one off make sure you do not nick the cable or you will be buying a new one. Now you have come to the hard part of the installation be ready to cuss and bleed take the rubber boot and intake manifold off the Pilot, boil some water dip the manifold in the hot water for about 30 seconds then take it out wipe off the water (don't want 1 drop in your engine) force it on the carb and tighten the clamp leave it on for a few hours. Take the other boot do the same but you want to position the boot on the carb so it will face the air box the right way sometimes after it cools it fits so tight you cant turn it so you want it right the first time :-) When you go to install the carb on the Pilot remove the manifold from the carb. NOW is a good time to check your reeds since with the bigger carb you will be using them more they need to be in top condition, when you install the reed cage make sure you clean the gasket surfaces and install a gasket on both sides of the reed cage I have not seen a Pilot yet that would pass a pressure test and not leak around the reed cage the first time around. When the intake manifold is installed and tight install the carb with the rubber boot still on the carb , you will probably have to push and turn like hell to get the boot on but it will go on trust me when you put the manifold in hot water and clamped it on the carb then let it cool for a few hours it actually stretched the boot to make it easier to install the carb :-) You can remove the carburetor from the intake manifold but you need to keep the rubber boot that goes between the carburetor and air box on, Install the intake using new gaskets then install the carburetor, don't worry about connecting the rubber boot to the air box until you get the carb on. Once you get the carb on stand back and look between the radiator and transmission look for the flat spot across the bottom of the carburetor where the float bowl is attached to the bottom of the carburetor make sure it is level you can not always go by the tab on the manifold to make sure the carburetor float bowl is level. You will need to further modify the throttle cable using a file remove the brass ferrule on the end of the cable and using a razor blade or knife trim back the black plastic outer covering [Pictures here] doing this will allow the cable to fit into the new carb. The picture below shows quite a bit, those that have not installed the 39mm PWK on their Pilot yet might find this useful. The pink arrow shows the fuel line routing. The green arrows are pointing to the new hose clamps, the old clamps will not fit. The yellow arrow is pointing to the idle screw, it is turned all the way in, you might need to remove the spring and cut off one or two coils on some Pilots if you can not get the idle you want. The blue arrow is pointing at a piece of vacuum hose you need to install to keep the dirt out, it should be a tight fit on the cable and the carb top not snug. Once you have the carburetor installed it is time to start jetting, start your engine up and adjust the idle and air screw let the engine warm up and start reading your plug or EGT gauge Start off by doing a plug chop at 1/2 throttle and then full throttle. for more jetting tips check out All About Jetting and HOW-TO Jet Your Carb If you see anything here that needs change or want to add a suggestion email me this is still in the development stages
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