TNOUBLESHOUIilO AUIDE

Outlined belorv are the proper prccedures br diagnosis and conection of

operating problems rclated to )@ur Mikuni TMX Series Carlcuretor
CHECK FOR: REMEDY:

WERFIOW
'1. Worn inlet valve or dirty inlet valve seat. '1.
Replace val\€ or clean valve seat.
2. lmproperluel le\€l in lloat bor{|. 2. Adjust floattabs for correcl luel lewl.
3. Damaged float bovl o{ing gaslct. 3. Relace o-ring
4. Loose float bor{|. 4. Tighten.

POOR IDLIl{G
'1.
1. ldle speed improperly adlusted. Adiust idle speeds.
2. Clogged bypass. 2. Clean.
3. Clogged pilot iet. 3. Clean iet.
4. Loose pilotjet. 4. Tighten tet.
5. Air leaking into system. 5 Tighten manilold and/or hose clamps.

POOR ACCELERAIION
1. Clogged pilotiel. 1. Clean.
2. Fuel level too loil. 2. Mjust le1ßl of float assembly.

HARO STARTII{G
1. Choke not operatino properly. 1. Clean orreplacaplungeii
2. Generälly djrty carburelor 2. Disassemble and clean.
3. Loose carburetor hose clamp. 3. Tighten.
4. Fuel ffirflw. 4. lnspect lloat assembly and inlet ulw end adjust
or replace.

POOR PERFORi'AI{CE
'1. ldle sp€ed improperly adiusted. '1.
Adiust idle.
2. Fuel overflw 2. lnsped float assembly and inlet nh€ and adiust
or replace.
3. Main iet loosened. 3. lnspect main iet and tighten.
4. Air leak in intake system. 4. Tighten manilold and/or hose clamps.
5. 0irty or clogged carburetor or air cleanei: 5. Clean.

POOR HIGH SPEED PERFORMAI{CE

1. Loose main iet. 1. lnsped main iet and üOhten.
2. lmpmper fuel le14l in float chambff 2. Mjust{loat assembly for correcl fuel level.
3. Dirt lodged in strainerin fuel tank 3. Clean straine[
4. Clogged main jet. 4. Clean.

ABN0RitAL C0M8USIt0l{ (FUEL MTXTURE)

1. Genenlly dirty carburetor 1. Disassemble and clean.
2. Dirty orclogged tuel line. 2. Clean fuel line or replace.
3. Air leakng into system. 3. Check mOuntir{.qüts or hose clamps l0r tightness. lit: r$
!i;l
Loss 0F P0WER (LEAi{)
1. Clogged luel line. 1. Clean.
2. Dirtyfuel tank. 2. Clean. :
3. Air leaking into system. 3. Check mounting nuts or hose cllnps I0r tightness.
4. Clogged fuel filter in luel tank. 4. Clean fuel filter
5 Genenlly dirty carburetor 5. Disassemble and clean.

toss 0F P0WER (RrcHl

'1. Dirty air cleaner element. 1. Clean or replace air cleaner element.
2. Throttle cable notworking. 2. Check throttle cable and adjust or replace.
3. Correct ietting lor change 0t altitude operation. 3. See tuning.
4. Loose jets. 4. Tighten jets.

MIKUNI AMERICAN CORPORATION

Motorcycle Carbu retor Division
8910 Mikuni Averiue, Northridge, CA 91324-3496 USA

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 WTNODUCTIOIT
MIKUITI TMXSEß'ES NACINE CANBUNEMN
jet can easily be accomplished by unscrewing the float bowl drain plug.
A new float valve system with independently moving floats, working in con-
junction with the main jet enclosed in a new baffle chamber allows the TMX
Carburetor to perform smoothly without hesitation across the roughest ter-
rain and under the most extreme lean angles and cornering forces.

Congratulations on your selection of the Mikuni TMX Carburetor for your

particular high performance application. We are positive you will be ex-
tremely satisfied with the performance gains and tuning ease we designed
it to provide.

ALWAYS RIDE WITH CARE AND SAFETY BOTH ON AND OFF THE
RACE TRACK. Never ride without a helmet, eye protection, and proper
protective clothing. Mikuni TMX Series Carburetors are legal in California
ONLY FOR RACING VEHICLES WHICH MAY NEVER BE USED UPON A
PUBLIC SIREET OR HIGHWAY. ln other states check for similar laws
which may apply.

MIKUNI AMERICAN CORPORATION

Motorcycle Carburetor Division
8910 Mikuni Avenue, Northridge, CA 91324€496 USA
With its intoduction the Mikuni TMX Series Racing Carburetor signified a
new generation of high performance carburetion from Mikuni designed
particularly for 2-shoke engines in motocross, off-road bike and AW racing
applications. The TMX Series will also perform extremely well in other ap
plications including llat track and road racing. For 4-stroke engine racing
applications the TMX Series will also provide a significant performance im-
provemgnt over stock carburelion systems although Mikuni recommends
use of the RS Series Carburetors which were designed particularly for 4-
stroke application.
An all new design, the Mikuni TMX Carburetor features a radial flat slide
design working in a smooth bore venturi that establishes a new perform-
ance standard for improved throttle response, along with a wider and
stronger overall powerband from the engine. These performance gains are
provided by the radial flat slide throttle valve design which produces a 400/o
greater boost signal lrom the air flowing past it for better throttle response
and an increased sensitivity to tuning. Very minimum tuning changes are
able to produce noticeable results in engine performance.
The TMXCarburetoris designed with a new lightweightand more compact
body design with easy maintenance and tuning features. The carburetor's
jet needle position may be changed easily and quickly. Access to the main
2

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 ITISTAL''//TION
E ENENAL NU CTI O NS
Belore you begin the installation of your Mikuni carburetor, take the time to c). I il
"IIST
read these instructions thoroughly.
.",u
tt--l
ll I fl+ff$.*,
WARNING: Gasoline is extremely flammable and can be explosive under
certain conditions. Do not smoke. Make sure your work area is well venti-
. Hj"-fl 1,,u"
lated and free from any source ol llame or spark. This includes any appli-
ance with a pilot light (i.e. a water heater in a garage).
llrll ",,'",""".
I

IMPORIANT Never remove a spark plug lead wire or fuel line while a mo-
tor is running as this can result in a fire or explosion. IA_r
_,y'
/Slide Cable End Flush
With TipOilnnor Cabte
ü
I.\
CHECK THROTTLE GABLE: lll And soidor
IV
lnstallation of your aftermarkel fMX Carburetor may require changing the fl flÜ Excess Solder

stockthrottle cable assembly's innercable. To determine if yourstock inner il

ll
cable is the correct length, disconnect and remove the throttle cable from
the carburetor. Check the inner cable's free length with the throttle control II
completely closed and the cable adjuster turned in all the way. Check the
il
inner cable's free length against the drawing. lf your inner cable does not ö
have a lree length between 86mm - 90mm, follow the next step to con-
struct a new inner cable.
t
3). Attach the throttle cable assembly to the TMX Carburetor.
4). Attach the air lilter boot adapter to the carburetor as shown in D).
5). lnstall the carburetor into the intake manifold and attach the air filter
bootto adapter.
Air Bd
o). Adaplor
,18
86mm-90mm lmml
H
1). Cut your stock inner cable so it can be removed from the outer
casing. Note: Do not damage outer casing, but simply slide inner
n-it
cable out.
2). Attach new inner cable supplied with your new TMX carburetor to the
throttle drum and slide the new inner cable into th€ outer casing. Set
tlt
Zcrtfo, t98zg
the cable adjuster as shown in diagram B). then follow the instruc-
tions in diagram C). for cutting and soldering the inner cable.
6). IMPOFrrANT lnstall fuel hose from fuel tank petcock to carburetor
B). using hose clamps. Use Yro" to 1/+" hose reducer if needed. lf fuel
hose is hard or cracked, replace it with new hose. TURN FUEL ON
AND CHECK FOR LEAKS.
4. Adjust the throttle cable to manufacturer's specifications. CAUTION:
Be sure the throttle operates smoothly and the carburetor throtile
slide returns to its idle position when the handlebars are turned from
lock to lock, and that the throttle cable does not pinch or bind when
3mm the handlebars are turned.
5

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 1q
3tc

112

It
FUEL METERING CIRCUITS
PILOT SYSTEM The Pilot System is comprised of two adjustable
components:
PILOI AR SCREW when turned in, richens the fuel mixture by reduc-
Pilot Jet ing the air flow into the Pilot System which operates from idle to approxi-
& Pilot
AirScrew l mately 1/4th open throttle. The effective adjustment range of the Pilot Air
Screw is between 1ä to 2 turns out. lf the Pilot Air Screw needs to be set
more than 2 turns out to achieve the best idle, the next smaller size Pilot Jet
I is required. lf less than 1ä turn is required, then a larger Pilot Jet should be
Jet Needle & used. The Pilot Air Screw should be adjusted to provide the highest engine
Clip Position RPM while the engine is at idle.
PILOr JET is the component supplying the majority of fuel from idle to
1/ath throttle position. The typical jet size should fall between No. 15 and
Throttle Valve Main Jet No.30. For selecting the correct Pilot Jet at idle, read the previous tuning
Cutaway directions tor the Pilol Air Screw. ll the engine appears to run too lean or too
rich off of idle, the carburetcir may require a size smaller or larger Pilot Jet
and/or the Pilot Air Screw may require adjustment.
6 7

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 JET NEEDLE The Jet Needle is the tapered rod that is positioned in the THROTTLE VALVE The Throttle Valve cutaway affects engine/carburetor
throttle valve by the 'E'-Clip. The taper of the needle increases the clear- response between lrbth tol/ath throttle slide position. The smaller lhe slide
ance between the Jet Needle and the fixed Needle Jet outlet as the throttle numberi the richer the mixture. Available range 3.0, 3.5, 4.0, 5.0, 6.0 (richer
is opened. As the air flow volume increases past the throttle slide, the fuel - leaner).
volume is also increased to maintain the correct airlluel ratio.
MAIN JET The Main Jet is located in the float bowl and can be removed or
NEEDLE'ELCLIP POSITION The changed through the float bowl drain plug hole. The Main Jet controls the
position of the 'E'-Clip in the Jet 'E'-Clip Position air/fuel mixture ratio from q+ths to wide open thottle position. The larger
Needle is used to correct or change the number stamped on the Main Jet the richer the mildure.
the airlfuel ratio between l+th and
%th throttle valve position. The'E'- Leaner When tuning the TMX Carburetor the tuning components being used are
relative to the throttle slide position, not engine RPM or actual vehicle
Clipcan be raised or lowered onthe
Jet Needle. To richen the fuel mix- 11 speed. Most tuning can be accomplished at relatively low speeds by mak-
ture the 'E'-Clip is lowered on the 2l ing note ol the approximate throttle position at which there appears lo be a
Jet Needle, raising the Jet Needle s
3l tuning problem. Make tuning adjustments by adiusting or changing the
tuning component controlling the fuel mixture al that throttle slide position.
position in the throttle slide. To lean
the fuel mixture the 'E'-Clip is 4l
raised on the Jel Needle, lowering
the Jet Needle's position in the
throüle slide.
5v FLOAT LEVEL ADJUSTMENT
lnvert carburetor and remove float bowl.
Richer
The Float Assembly's actuator tab should just begin contact with the Nee
OPTIONAL JET NEEDLES To cor- dle Valve Assembly when the bottom of the Float Assembly is 20mmfrom
rect the fuel mixture at lÄth to l/+th carburetor bottom as shown. Make required adjustments by bending actu-
throttle slide position it may be nec- ator tab.
essary to change the Jet Needle. o.D.
The Jet Needle will have a series of ActuatorTab
Straight Portion
numbers stamped on it.

Example: 6EJ12-55. The numbers

55 indicate that the outside diame-
ter (O.D.) of the Jet Needle is
-T--
2.55mm. The smaller the O.D. the
richer the mixture. The larger the 'E'Taper
number the leaner the mixture.

Typical Jet Needles Available:

6EJ12-57
6EJ12-56
Leaner
__L
TMXss 6EJ12-s5 ^I
6EJ12-s4 .t I

6EJ12-53 Richer 'J'Taper

6EN11-54 Leaner
TMX35 6EN11-53
6EN11-52
t
Richer

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 TMXSEHES/flMX 35 and 38 MIKAM TCCESSOf,'ES
MIKUNITMX SERIES PAMS LIST
No. De$dplion TMX CARB PAM NUMBERS
ORDERING INFORMATION
1 MIXING AOry CARA
2 JET NEEDLE
ss€eF
J8-SEETUNING
AORE SPIGtr All Mikuni accessories are available from your local motorcycle parts
SIZE OD
3 COr'ER, CARB TOP 77619014 TM35-1 35mm 40mm dealeri Mikuni distributor, or direct by mail from Mikuni American. No
4 LOCKNUT, ADJUSTER B30t247 TM&27 38mh phone orders, please. Mail your order with certified check, money order,
5 CAP RUBBER vMut2a2 TM$-18 38mm
6 ADJUSER. CABLE VMOTT VISA or MASTERCARD information. California residents include 61ho/oCA
7 O-RING. rcPCOVEF 61&9m
8 [Link], NEEDLECLIP BSg126 sales tax.
9 FING, AETAINING TMS/g
1O AOJUSTEFI, IDLE STOP m+25008 MIKUNI POCKET TUNER
11 SPRING. IDLE ADJUST
12 PLUNGER. SIAMERASBY
13 SCREW AIR ANUSTEF
N110m
lMgm
60336002
/-r
g A handy pocket size slide calcula-
tor which can be used to determine
14 SPRING, AIRSÖREW
15 CHAMAER. FLOAT BtrL TMgß required jetting changes in Mikuni
16 VALVE SEAT, NEEDLE 8m.260023.5 carburetors due to changes in am-
17
1A
PILOTJff
MAINJET
vM2Z210
4M2
VMß15
'-Ü bient temperature, altitude, or both.
19 ARM. FLOAT
I'QJ The Pocket Tuner is applicable to
rc NEEOLE VALVEASEMALY
21 [Link]
7&26m5
vMmßr5
&10
rt
\/) l2-" fi_" both single and multi-carburetor

"€
22 GRING. NEEOLE VALVE
8 CAE FLOAT RflAINER vM2d42 ll-- applications on two-stroke and
24 SCREWTOPCOVEF cw2-ßr2 '--+=,1 t\,,1 E..s four-stroke engines. lt also comes
25 THROfrLE VALVE ß241n2
/\lnl a_. with a guide lor determining rich or
S
HIIl!,,
SPRING, TV 7S1S19
27 HO6E. VENf 8&24011 lean carburetor conditions.

U G\ll _eq\
28 SCREW. FLüT BO/VL cw2{308
ä HOSE, Or'ER FLCIil w2m22 MIKUNI POCKETTURNER
S FLOAI LEFT SIDE 8595m21
Part No. MK-SSGTNR $2.95
31 GRINg. DFAIN PLUG vM2&29
32 DRAIN PLUO TMß{
33 FLOAT, RIGHTSIOE 859-520m
lltLj
MIKUNI RACETEAM
A GASKEI, FLOAT BO\A/L
PAtrNUMBEB€O€S}=
TM38/52
,^^\ APPAREL
NO AVAILABLE STOCK
,x=5\ MIKUNIT-SHIRI SILVER
S, M, LG, XLG, $9.95
Part No. MK4C/-3
MIKUNI [Link], TURQUOISE

\ll\\
il
S, M, LG, XLG,
Part No. MK-407.4 $9.95
ri MIKUNI KNIT SPOHT SHIRT
_, ]\ I SILVER, S, M, LG, XLG,

//
t) ,@[ Part No. MK407€ $17.95
MIKUNI VENTED CAP

/,8
'/E
,"_-tb
!€
SILVER, ONE SIZE,
Part No. MK4O8-3 $5.95
MIKUNI CORDUROTCAP
f\@ SILVER, ONE SIZE,
ts Part No. MK-4O&7$12.95
MIKUNI DAYTONA TEAM JACKET

"k \=-,'
SILVER, S, M, LG, XLG,
Part No. MK-52G7 $49.95
MIKUNI DECAL KIT
ASSORTMENTOF 1Z
Part No. MK-5o2-ASrMT $9.95
TL.,, MIKUNI EMBLEM PArcH
t9
IJ-'" RED/wH|TABLUE,
\ Part No. MK-50$1 $2.00
10

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