K1 carb refit after 4 years in storage

[netsurfer]

Hi all,

Due to my throttle getting tighter and tighter over a period of 6 months or so, I (stupidly) decided to take the carbs off my 2001 650 to free up the shafts etc.

Various reasons meant that I still (4 years later) haven't got the carbs repaired.

I have a few problems....

1) Air leaks at shaft seals
2) Damaged screws
3) Don't know if I can remember how to refit the carbs(!)

So I guess one step at a time, is it possible to get repair kits for these carbs?

Was an active member in these forums around 7-8 years ago, but my login no longer exists, had to re-register :(

Cheers

Pete

[R1ffR4ff]

For seals and electrics and fasteners get some ACF50.Absolute ,"Dog's Danglies",


http://www.acf-50.co.uk/motorcycle.htm

Also bookmark the partsfiche for your model,


https://www.cmsnl.com/suzuki-sv650-1999-x-usa-e03_model16251/partslist/

I use these in conjunction with Manuals when servicing/Stripping and refit of parts.

HTH :)

[netsurfer]

Hi guys, thanks for the responses.

The seals are for the throttle shaft and screws to hold the butterflies on these shafts too. Tried posting a photo but cant figure it out :rolleyes: tells me its not a valid image file.

Cheers
Pete

[R1ffR4ff]

Just to add.If the bike came with the,"Toolkit" it contains JIS Screwdrivers.

HTH :)

[Teejayexc]

Just to add.If the bike came with the,"Toolkit" it contains JIS Screwdrivers.

HTH :)

The 'toolkit' is about the same ****e quality as the screws!

[mikerj]

The 'toolkit' is about the same ****e quality as the screws!

A cunning design to protect the screw heads, the screwdriver rounds off before they do ;)

[netsurfer]

I presume there was a steel shortage when they made the screws so they substituted it with chocolate.

I have managed to get my hands on another pair of carbs, but the mixture screw in one of them has been butchered and wont turn (the slot is stripped)

Going to see if I can get it drilled out and make one set out of two!

Will update with the good or bad news soon :)

Pete

[netsurfer]

Since starting this thread, I've found the tax disc and it turns out it was last on the road in 2007, so actually 10 years off the road!

Ok I've managed to split the carb where the air screw goes in (just the outer part, no air leaks) - it's not for moving even with heat, drill & stud extractor!

Have decided to try them as they are in case the screw doesn't need adjusted. If it does i'm afraid i'll have to write off the rear carb and try to find another one or attempt to fix the original with parts from the s/h pair I got.

This will involve removing the JIS screws from the throttle butterflies, does anyone know what size the heads are? It seems there are 3 common JIS screw head sizes, P1 P2 and P3

Don't want to get a full set as they are about £10 each!

Cheers
Pete

[R1ffR4ff]

Since starting this thread, I've found the tax disc and it turns out it was last on the road in 2007, so actually 10 years off the road!

Ok I've managed to split the carb where the air screw goes in (just the outer part, no air leaks) - it's not for moving even with heat, drill & stud extractor!

Have decided to try them as they are in case the screw doesn't need adjusted. If it does i'm afraid i'll have to write off the rear carb and try to find another one or attempt to fix the original with parts from the s/h pair I got.

This will involve removing the JIS screws from the throttle butterflies, does anyone know what size the heads are? It seems there are 3 common JIS screw head sizes, P1 P2 and P3

Don't want to get a full set as they are about £10 each!

Cheers
Pete

BTSTGTTS on seized studs/bolts etc.

There's a great home-made rust release/anti- seize release fluid.
50/50 mix of Brake fluid and Acetone.

I also have some left-hand Drill bits.

As for the JIS sizes not sure but an old trick,once you have used some anti-seize release around the screws,is to use a Thick rubber band on top of the Screw Cross point screw head and push the screwdriver into it and the screw-head,

It gives extra purchase.Also I always tighten screws a little before trying to release them.It cracks the corrosion seal.

I work on Aircraft and so I also have,"Screw-Grab" in my garage,


https://www.ebay.co.uk/itm/SCREW-GRAB-HELPS-TO-REMOVE-OR-TIGHTEN-SCREWS-BRAND-NEW-FREE-P-P/262422007713?hash=item3d19920fa1:g:qFwAAOSwKfVXK1w I


I also have one of these for accurate localized heat application,

https://www.ebay.co.uk/itm/Welding-Soldering-Inflatable-Tool-Mini-Butane-Gas-Blow-Torch-NO-BUTANE/222903384460?epid=1566154982&hash=item33e613b98c:g:x0kAAOSwlp1Zu8~u

PS
If by,"Stud Extractor" you mean an,"Easi-Out" then only buy quality as cheap ones will bite you in the Bum!

[andy650]

I had the throttle shaft seize on my Curvy a few years back.

I did manage to get the butterfly screws out with "normal" screwdrivers, with no damage. Sorry don't remember what I used. When refitted I used loctite as I couldn't re-peen the ends.

One of the throttle shaft seals was visibly damaged, but I could not find a replacement anywhere (part number is not listed), so I took a risk and rebuilt with the damaged seal (it wasn't that bad).

3 years later no issues whatsoever. If it ever does cause a problem I will buy a rubbish set of carbs and recover a hopefully good seal from them.

[netsurfer]

Regarding the seals - I just cannot remember what they look like - whether they are a regular oil seal or an O ring. If an oil seal type - they tend to be standard sizes so any oil seal seller would be able to help if you take the carb to them.

This infuriating link shows you everything (on a BDST carb) except part numbers:

http://www.litetek.co/Guide_MikuniBDST_ThrottleShaftSeal.html

Thanks! I had a nosey around on the litetek site and found on the detailed rebuild guide that the carb is also used on a Yamaha FZR-400RR so went into this section on their site and found the Yamaha part number! 256-14997-00

So, if it comes to needing seals, i'll add them to my motorcyclespareparts order that I need to place for some other genuine items.

Pete

[R1ffR4ff]

Thanks! I had a nosey around on the litetek site and found on the detailed rebuild guide that the carb is also used on a Yamaha FZR-400RR so went into this section on their site and found the Yamaha part number! 256-14997-00

So, if it comes to needing seals, i'll add them to my motorcyclespareparts order that I need to place for some other genuine items.

Pete

That's great work and well worth knowing :D

[netsurfer]

Slowly getting there, carbs refitted but waiting for some other bits before I try to fire the old girl up.

Meanwhile I’ve been trying to diagnose a sticky throttle and while I think I’ve sorted it (cable adjustment) I realise I have routed the idle adjust cable incorrectly. On closer inspection I think I may have also routed the rear choke cable incorrectly too.

Can anyone confirm does it go above or below the frame crossmember that is between the two carbs?
Currently I have it sandwiched between the carb frame and the crossmember but it looks like it might wear over time.

Trying to attach a photo to help explain.

https://uploads.tapatalk-cdn.com/20180516/2dda01f9437a675e8568e7909533b205.jpg


Sent from my iPhone using Tapatalk

[netsurfer]

Decided to remove the carbs and refit the cable below the frame, glad I did - the choke cables were partially seized allowing only about 30% travel. All freed up now, waiting for new choke O-rings before refitting.

Anyone used motorcyclespareparts.eu before? Just wondering how quick the delivery is :)