K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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-sv650-1...251/partslist/

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

HTH :)

Re: K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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

HTH :)

Re: K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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

Re: K1 carb refit after 4 years in storage
 

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-GRA...wAAOSwKfVXK1wI


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

https://www.ebay.co.uk/itm/Welding-S...kAAOSwlp1Zu8~u

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

Re: K1 carb refit after 4 years in storage
 

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.