Carburetor Stealth 500: detailed instructions for adjustment

Do no harm!

It is no secret that many owners of Stealth 500 ATVs criticize the design of the carburetor installed on the car, believing it to be the main culprit for the incorrect operation of the fuel system and problems with the traction characteristics of the engine. There is no doubt, there are certain grounds for such statements. But when trying to do their own repairs, some motorcycle owners forget that interfering with the operation of a complex device without the appropriate knowledge and training can bring irreparable harm rather than benefit.

Make no mistake

Let's try to clarify. First of all, the statement that the Stealth 500 carburetor was allegedly made in Japan is not true. As often happens, products are manufactured in China under license (or perhaps without it), and it can only be regarded as a product copied from successful Japanese models. The carburetor of the Stealth 500 GT and other modifications of the popular ATV has the factory marking PD36J. It is a design with one float chamber and one diffuser and, during normal operation, ensures stable engine operation in all modes with fairly economical fuel consumption.

Be consistent

It should be understood that there are reasons for increased fuel consumption and unstable engine operation. It is necessary to accurately determine the cause of the malfunction before proceeding with its elimination. But if there is still an assumption that the carburetor of the Stealth 500 ATV is to blame, first of all, you should carefully check the tightness and reliable fixation of the fuel and air hoses. It is their leakage that can be the source of problems. And only if everything is in order with this, you should think about more complex repairs.

There is an opinion that the main reason for the poor performance of the unit is a defect during its manufacturing process. Indeed, there are carburetors with cracks in the body or improperly processed air and fuel channels. If this is indeed the case, then the part will have to be replaced. But if no obvious damage is found, adjusting the Stealth 500 carburetor can solve the problems that have arisen. But first you need to make sure there is no contamination. To do this, the part will have to be removed, disassembled, and, if necessary, washed. It is important to pay attention to the integrity of the gaskets and be sure to replace damaged ones.

What you need to have to repair an ATV

ATVs are known to be used in off-road conditions. They can even be called extreme. The motorbike can be quickly restored if you have everything you need. Using a tire pressure gauge, you can quickly measure the pressure inside your tires. Tires can be successfully repaired using a special kit. Also in stock should be replacement nuts, bolts, a screwdriver, a towing cable, hexagons of different diameters, pliers, and an open-end wrench.

READ ALSO: Gasoline or diesel? Which engine should I buy Gazelle Next with?

Operations Performed

Let's face it, servicing a device installed on an ATV is not very convenient. All that the developers took care of for such a case when designing the Stealth 500 carburetor was adjusting the idle speed. This is done with the engine warmed up to operating temperature by turning the adjusting screw. The optimal mode is considered to be when the tachometer needle is set at 1600 rpm.

In order to change the qualitative composition of the fuel mixture, the part will have to be dismantled. The design provides two stages of adjustment.

Rude. It is done by changing the position of the installation washer on the dosing needle rod. To do this, you have to unscrew the two fastening screws and remove the diaphragm along with the needle and piston. Only after this will it be possible to rearrange the ring into one of the five positions provided by the manufacturer. Such an adjustment affects the total amount of fuel mixture entering the engine, changing the traction characteristics of the engine and gasoline consumption.
Thin. To do this, you will have to use a screw, initially hidden under a plastic plug. The plug will have to be removed. After this, the screw is tightened until it stops, and then unscrewed 1.5 - 2.5 turns, after which the plug is installed in place. In this way, it is possible to achieve the optimal mixture composition at idle speed and in transition modes.

You can judge the result of the work done by the color of the electrodes of the spark plug removed from the engine. If everything is in order, then after 15 - 20 minutes. When the engine is running they will be light brown in color. Black, sooty electrodes indicate excess fuel. A whitish coating indicates a lean mixture. In both cases, the position of the screw will have to be changed slightly. Be prepared for the fact that you will have to do this operation several times.

Improvements to the popular STELS ATV 500 GT ATV model

STELS 500 GT is a utilitarian ATV for solving a variety of tasks. High ground clearance of 26 cm and large 26” wheels, together with metal front bumper protection, give the STELS 500 GT high cross-country ability. Durable luggage platforms and a wide two-level seat allow you to confidently go on long raids on an ATV. STELS 500 GT is one of the most popular models in the STELS ATV line. That is why the model is constantly being improved. In the new season, more than 60 improvements will be made to make the STELS 500 GT even more convenient to use.

DASHBOARD

NEW FEATURES: ① Digital tachometer display showing engine speed ② Engine oil pressure indicator ③ Gear selection indicator

NEW PARTS: C500-3800100A Instrument panel assembly. GB70-85 Screw M5×8 C500-3800101A Dashboard visor GB5787-86 Screw M6×12 C500-3800102A Ignition switch plate GB6177-86 Nut M6 C500-8302069 Installation plate.

LOW OIL PRESSURE WARNING

NEW FEATURES: Changes to the engine crankcase and added an oil pressure sensor. When the oil level drops, a warning signal will be displayed on the digital speedometer screen.

NEW PARTS: C500-8302072 Oil pressure sensor.

MANUAL STARTER

IMPROVEMENTS: ① Double ratchets ② No rough spots on the ratchets ③ Newly designed pressure plate ④ No rough spots on the outlet

NEW PARTS: 192MR-1000100A Magneto Cover 192MR-1000120 Starter Disc Assembly 192MR-1000116 Pressure Plate 192MR-1000117 Bolt 192MR-1000115 Retaining Ring 192MR-1000109 Handle Stop

CARBURETOR MANIFOLD

IMPROVEMENTS: ①Separate design (eliminates two problems of the previous version of the part: 1. The quality of the connection between the rubber and metal parts 2. The rubber around the connection is too thin) ② The rubber used is mixed with PVC (polyvinyl chloride) and is frost-resistant (-30℃), fuel- and ozone resistant.

NEW PARTS: 192MR-1003027 Carburetor Manifold 192MR-1003026 Carburetor Inlet Tube C250-1900004 Carburetor Tube Connection 192MR-1000039 Clamp 44-64

BEARING BASE

The new bearing base is made of iron, making it stronger.

GEAR SHIFT

DESCRIPTION OF THE NEW GEAR SHIFTING SYSTEM: At engine speeds less than 1500 rpm. and when driving at a speed of less than 5 km/h, a gear shift indication is displayed on the instrument panel. After pressing the gear shift knob and pressing the brake pedal, you can select the desired gear.

NEW PARTS: 192MR-1001900 Gear shift mechanism assembly. 192MR-1001901 Stopper 192MR-1001902 Sliding sleeve 192MR-1001903 Sliding part 192MR-1001904 Connecting plate 192MR-1001905 Spring 192MR-1001906 Reel 192MR-1001907 Guide sleeve GB345 2.1-92 O-ring 5×1.8 192MR-1001909 Wire/cable cover 192MR -1001911 Rod 192MR-1001912 Handle GB70-85 Screw M5×12 192MR-1001913 Restrictor plate 192MR-1001914 Rod/rod/rod GB5787-86 Screw M6×28 192MR-1000004a Guide screw 192MR- 1001920 Wiring harness C500-1504100 Gear shift lever assembly C500-1504106 Gear shift lever C500-1504120 Lever assembly. C500-1504101 Mounting socket GB818-85 M5×8 screw C500-1504102 Switch C500-1504130 Wiring harness

FRONT DIFFERENTIAL RELAY

IMPROVEMENTS: ①Gears are made of more durable material ②More powerful motor with more torque ③Increased accuracy of gear mating.

NEW PARTS: C500-2300600 Front Gearbox Relay C500-2300620 Mode Switch C500-2300601 Gearbox Relay Mounting Plate C500-2300602 Motor Mounting Plate P660-2300603a Rubber Boot GB/T5787-1986 M6×25 Screw C500-2300603 Torsion spring C500-2300604 Gears C500-2300605 Spring base 1 C500-2300606 Spring base 2 C500-2300607 Guide pin C500-2300608 Screw M5×34 GB/T13871-92 Oil seal 8x16x5 C500-2300630 Cable/wire

DIFFERENTIAL CONTROL UNIT

IMPROVEMENTS: ① The new control unit is electronic and overload protected, which improves its reliability. ② If it is impossible to properly mate the gearbox gears with the fork when switching 2WD/4WD modes or when the differential lock is engaged, the gearbox gears automatically return to their original position. If correct pairing does not occur after 20 attempts, such attempts are stopped and the corresponding indicator lights up.

NEW PARTS: C500-3704700A Differential control unit C500-8301039 Mounting plate GB/T5787-1986 Screw M6×16 GB/T6177.2-2000 Nut M6

HINGE BOOT

IMPROVEMENTS: ①New boot protects better from dust and increases the life of the hinge.

NEW PARTS: C500-2901113 Boot C500-2901114 Clamp

CRANKSHAFT AND PISTON PIN IMPROVEMENTS:

①The hardness of the connecting rod has been increased ②The assembly quality of the crankshaft and piston pin has been improved.

FRONT CVT PULLEY

Build quality through 100% inspection, marking and grouping of parts. The central shaft of the variator (C500-1502201) and half of the variator pulley (P800-1502250) are placed in different groups depending on the size, then the pairs that best fit are selected. All parts for assembling the variator are inspected. Checking the operation of the pulleys after cooling them to -20 degrees.

At the beginning of the 2013 season, we expect the results of test drives and the availability of the modified STELS 500 GT for sale. We hope that the improved ATV model will meet all the requirements of the most demanding riders.

Comments: