Removing the carbs for the first time...

[ianreb]

Alright guys... I finally took the plunge and started the process of cleaning the carbs myself. I have looked all over the boards and found the tutorials quite helpful (thanks for that).

So far, I've removed the tank, air box, throttle cables, and all of the hoses necessary to pull it out. I've also loosened the clamps on carb 1, 2, and 4 (at least i think i loosened the right thing... 3mm allen extension). 3 is the only one left and I'm having quite a bit of trouble getting to it.

My question: Since I loosened 3/4 clamps, I tried nudging the carbs around a bit to see if there was any more movement. Did not budge a bit. Am I missing something or is the 3rd carb's clamp the only thing I have left to fully pull the carbs out? It feels like a lot more is holding it down.

Sorry if this has been done before.

[kevlarian]

I think that is all you need! I have only removed my carbs twice. Both times, it was to replace the engine (don't ask). I don't remember any particular trick to it. They are on their TIGHT, so you will have to wiggle it around a bit to nudge them loose. But otherwise, they should come off clean. Good luck with your cleaning, and take lots of photos and post it up so we can see your progress.

.kev

[ianreb]

well... scratch that. I went back out there and fiddled with it. Came right out, no problem this time!
i'll clean the carbs tonight and put them back in tomorrow... WITH PICS!

During this process I also changed the spark plugs and I'm thinking of doing the coolant while I'm at it. Any advice on cleaning or reinstalling the carbs that is not already on the master list tutorial?

[ianreb]

what particular objects am I not supposed to soak? anybody have pictures of these items?

[97catintenn]

If you're talking about soaking items in carb cleaner, just keep all the rubber stuff out, like diaphragms and o-rings. Chase the jets with anything you have handy, just doing a visual inspection has been know to fail a couple of members here.

[ianreb]

If you're talking about soaking items in carb cleaner, just keep all the rubber stuff out, like diaphragms and o-rings. Chase the jets with anything you have handy, just doing a visual inspection has been know to fail a couple of members here.

what do you mean by that?

[97catintenn]

The jet and the jet holder has small holes in it. You want to run a small wire through there to manually clean them out. I was taught to use the term chase. The wire needs to be softer than the jet so that you do not scratch the passage that fuel runs through.

[ianreb]

The jet and the jet holder has small holes in it. You want to run a small wire through there to manually clean them out. I was taught to use the term chase. The wire needs to be softer than the jet so that you do not scratch the passage that fuel runs through.

thanks for clearing that up. I didn't know that's what you were talking about. I've heard guitar strings are perfect for that.

I'll post pics of my process tomorrow and make sure I did everything correctly before I put the carbs back.

[Slimy]

Next time you need to remove the carbs, just pull them off! Rock them back and forth until the boots come loose and the whole thing comes off. Then you can mess about with clamps and such like. Personally I've not moved my clamps since I did it the first time, I just pull the carbs off and push them back on when I'm done. I've also put a smear of lithium grease on the inside of the rubber to get them to seat better.

[ianreb]

i have cleaned everything... but I can NOT for the LIFE of me get the pilot jets out of the hole. Ive tried 3 different flathead screwdrivers (the jets arent stripped). How important is it to get these out and clean them? It seems impossible.

this one:

[hk'dontoys]

deleted thanks to the pic!

[lakey009]

Just a thought have you tried putting all of your weight over the screw driver then turn, just because some people go abit easy with thing's like this i know you are already doing this no doubt. Mine were the same just doing them now as i type and i had to just about lift myself onto the screw driver then turn

[ianreb]

Just a thought have you tried putting all of your weight over the screw driver then turn, just because some people go abit easy with thing's like this i know you are already doing this no doubt. Mine were the same just doing them now as i type and i had to just about lift myself onto the screw driver then turn

yea, ive been pressing it like an ape. I haven't stripped the screws, but I have broken two flathead screwdrivers

EDIT: i ended up getting them loose by custom grinding down one of the screwdrivers i broke.

[lakey009]

Put the screw driver into the screw head and hit the top of the screw driver not hard just about the weight of a hammer falling for 2" do this once or twice tops then try to crack the screw out.

[KBacon]

Yeah... I have one of those screwdrivers w/ the tips that flips from phillips to flathead... and that's the only one that I have that will fit down that hole.... since it doesn't have the flared sides.

[97catintenn]

i have cleaned everything... but I can NOT for the LIFE of me get the pilot jets out of the hole. Ive tried 3 different flathead screwdrivers (the jets arent stripped). How important is it to get these out and clean them? It seems impossible.

The pilot jet is the most problematic, so it ranks pretty high.

[ianreb]

So here are some pictures... I ended up not taking as many as I wanted to. My camera quality is horrible and it got worse as time went on.

1. Carbs Still in the bike with everything disconnected:



2. Carbs removed from the bike:




3. Tools used



4. Organization containers (I used 8 total)



5. I ended up having gas spill out of here...



6. no gas came out when I tried draining the carbs by taking out the plug. This is after I already took them apart, gas will come flowing out of here, so be prepared



7. After draining the gas, I started unscrewing the 4 screws on the vacuum chambers... WITHOUT STRIPPING THEM



8. Took the cap off, removed the spring, and the rubber with the jet needle.







9. Some organization. I wrote the carb number for each set in the bowls and on the carbs



10. Flipped everything over to dig into the float bowls.



11. Remove the four screws keeping everything organized and take the cover off.



12. Look at that green gunk! Disgusting!



13. Removing the top jet from the needle jet with a flat screwdriver. After that, I removed the needle jet (8mm0 [not pictured]



14. I removed the pilot jet with a modified flathead screwdriver. removal is not pictured but here is my flathead screwdriver that i had to grind down. I ended up breaking two smaller flathead screwdrivers



15. I removed the screw that holds the float down



16. Carefully pulled the float out making sure not to drop any of the small parts.



17. I removed the screw that holds the valve seat down... took some pliers with rubber to take the valve seat out.



18. Everything removed, separated in containers.





19. I cleaned everything with carb cleaner, making sure not to get any rubber pieces or o-rings wet with it. I put everything back together in reverse order.

[ianreb]

Tips:

-For Tank/Carb Removal I used this thread: viewtopic.php?t=38920
-For Carb Cleaning I used this thread: viewtopic.php?t=32680

-On carb removal: label all of the plugs and wires with tape so you don't get mixed up when you reinstall everything
-clean up any coolant that is spilled
-With the carbs off, I went ahead and changed the spark plugs.
You will see a panel with a lot of electrical wires that is held on by two 10mm bolts.
Remove the bolts and you will have direct access to the spark plugs from the top.
-I also made sure to check my coolant level and add any if needed (50/50)
-The screws and bolts on the carbs were put on by an ape... Basically had to use all of my weight to make sure I did not end up stripping anything.
-Do not get anything rubber wet with carb cleaner... that includes any o-rings
-Have paper towels, sewing needles, compressed air, and q-tips ready for cleaning everything.
-DO NOT GET CARB CLEANER IN YOUR CUTS ON YOUR HANDS... hurts

[ianreb]

My Questions

1. Does anyone have any tips for getting the throttle cables back on when reinstalling the carbs?
2. I took this picture down in the holes of the bike that the carbs connect to. It looks really nasty. Is it supposed to look like this? If not, how can I clean it and what is wrong?




3. The is this zig-zag tube the carb coolant line? If so, i didnt have one that long.... wtf is that normal? you can see mine on number 10 of my post

[ianreb]

bump before bed. hopefully someone can help me out with my questions