THIS MOD WILL ONLY WORK ON PRAIRIE 650/700, VFORCE AND BRUTE 650 SRA MODELS.
Hi all, Thought I would post this up as I did a search on here for crossover intakes and nothing came up.
I got the info for this mod from Kawieriders and jetting help from vforce john, so thanks to all that helped out.
It's pretty easy mod to do and also very cheap with excellent power gains. The biggest gains are on a stock motor of about 5hp and modded motors around 2-3 hp(vforcejohn dyno tests). I also polished the carb slides while I was at it and I think this contributed to the excellent throttle responce I now have.
Tools and parts you will need are as follows,
Electric low psi(approx 3.5 psi) fuel pump. Mr. Gasket 42s I think is the one they suggested over on kawieriders.
Some earlier model brutes and prairies had the electric fuel pump from the factory so no need to get it if you already have an electric pump standard(mine is an 09 650 sra and I needed to buy the electric pump as mine was vacume operated).
3/4" or 1" copper pipe for the crossover tube.
Black silicon sealant.
Some nipple block off caps.
Asorted jets as you useualy need to fatten up the jetting after this mod. Stock jetting on mine was 40 pilot front, main 138. Rear 40 pilot and main 142. Fuel screw front 1.25 out, rear 2.25 out.
After the mod my jetting is front pilot 40, main 142 and rear pilot 40, main 145 fuel screw 3 turns out both front and back with 1 #4 washer as a spacer for the needles. I think I could have gone 42 on the pilots but I couldn't get any but mine runs real strong from top bottom to top, no hesitations or popping with the above jetting at sea level. Stock air box.
Dremel tool or similar for for smoothing crossover tube and polishing slides.
Hacksaw.
Various basic tools for removing the body plastic, airbox ect.
Soldering iron or crimps/conectors for wiring fuel pump.
The biggest PITA was disconecting and reconecting the choke cables lol.
Once you have the intake and carbs out mark where the crossover tube will go on the rubber intake boots, cut the holes out carefully a little smaller then your tube then cut your copper tube to length and insert into the holes you cut in the rubber intakes.
Smooth the copper tube so there are no lips ect when installed in the rubber intake boots. Make sure the rubber intake boots are clean so your sealant will stick. Add sealant on the outside of the copper tube transitioning onto the rubber boots and smooth out as best you can.
Now bolt the intake only back on the motor and let sealant set, you will have to do this a couple of times until you are happy with the build up and shape.
Remove your vacume fuel pump and wire in your new electric pump as per instructions in this link. http://www.kawieriders.com/forum/in...el-pump-mod-brute-650-s-vacuum-fuel-pump.html
Polish your slides as per this link. http://www.kawieriders.com/forum/kawasaki-brute-force-prairie-bayou/96424-polishing-carb-slides.html
Re-jet and bolt everything back up and enjoy your new found power and throtle responce for very little cost. My 650 sra can not get traction after doing this mod on stock tires! Once I get my new tires this thing is gunna want to hook up and wheelie all day! Very noticeable seat of pants gain from this mod, I highly recommend it.
Here are some pics of mine.
Old fuel pump and vac lines removed
New fuel pump installed.
You can see in this pic of the intake where I used the rubber block off nipples to block the vacume lines that are not needed anymore.
Pics of crossover installed.
Polished carb slide.
Hi all, Thought I would post this up as I did a search on here for crossover intakes and nothing came up.
I got the info for this mod from Kawieriders and jetting help from vforce john, so thanks to all that helped out.
It's pretty easy mod to do and also very cheap with excellent power gains. The biggest gains are on a stock motor of about 5hp and modded motors around 2-3 hp(vforcejohn dyno tests). I also polished the carb slides while I was at it and I think this contributed to the excellent throttle responce I now have.
Tools and parts you will need are as follows,
Electric low psi(approx 3.5 psi) fuel pump. Mr. Gasket 42s I think is the one they suggested over on kawieriders.
Some earlier model brutes and prairies had the electric fuel pump from the factory so no need to get it if you already have an electric pump standard(mine is an 09 650 sra and I needed to buy the electric pump as mine was vacume operated).
3/4" or 1" copper pipe for the crossover tube.
Black silicon sealant.
Some nipple block off caps.
Asorted jets as you useualy need to fatten up the jetting after this mod. Stock jetting on mine was 40 pilot front, main 138. Rear 40 pilot and main 142. Fuel screw front 1.25 out, rear 2.25 out.
After the mod my jetting is front pilot 40, main 142 and rear pilot 40, main 145 fuel screw 3 turns out both front and back with 1 #4 washer as a spacer for the needles. I think I could have gone 42 on the pilots but I couldn't get any but mine runs real strong from top bottom to top, no hesitations or popping with the above jetting at sea level. Stock air box.
Dremel tool or similar for for smoothing crossover tube and polishing slides.
Hacksaw.
Various basic tools for removing the body plastic, airbox ect.
Soldering iron or crimps/conectors for wiring fuel pump.
The biggest PITA was disconecting and reconecting the choke cables lol.
Once you have the intake and carbs out mark where the crossover tube will go on the rubber intake boots, cut the holes out carefully a little smaller then your tube then cut your copper tube to length and insert into the holes you cut in the rubber intakes.
Smooth the copper tube so there are no lips ect when installed in the rubber intake boots. Make sure the rubber intake boots are clean so your sealant will stick. Add sealant on the outside of the copper tube transitioning onto the rubber boots and smooth out as best you can.
Now bolt the intake only back on the motor and let sealant set, you will have to do this a couple of times until you are happy with the build up and shape.
Remove your vacume fuel pump and wire in your new electric pump as per instructions in this link. http://www.kawieriders.com/forum/in...el-pump-mod-brute-650-s-vacuum-fuel-pump.html
Polish your slides as per this link. http://www.kawieriders.com/forum/kawasaki-brute-force-prairie-bayou/96424-polishing-carb-slides.html
Re-jet and bolt everything back up and enjoy your new found power and throtle responce for very little cost. My 650 sra can not get traction after doing this mod on stock tires! Once I get my new tires this thing is gunna want to hook up and wheelie all day! Very noticeable seat of pants gain from this mod, I highly recommend it.
Here are some pics of mine.
Old fuel pump and vac lines removed
New fuel pump installed.
You can see in this pic of the intake where I used the rubber block off nipples to block the vacume lines that are not needed anymore.
Pics of crossover installed.
Polished carb slide.