Good stuff!!!! educational and timely

Check out additional link:
www.factorypro.com/tec...gines.html
may be the extra mile you need

This article is great. Thanks Rick.

Being a complete n(b)oob who plans on trying to rebuild my carbs over the winter, can anyone give me a complete list of what I will need (Parts and tools) before I start this endeavour? I don't want to have to run to the store once I get started.

And I realise this lis tmight change as I take things apart and find/make problems.

TOOLS NEEDED:

* time.
* patience.
* paper, pen, and a notebook.
* ZIP-LOCK BAGGIES OF VARIOUS SIZES.
* a clean, semi-uncluttered, well-lit and well-ventilated area to work in.
* a strong flashlight.
* a magnifying glass.
* a digital-cam would be a huge bonus.
* haynes or clymer workshop manual.
* yamaha service manual.
* xjbikes.com threads already bookmarked.
* paper towels and shop rags.
* access to ultrasonic cleaner.
* access to tumbler or glass-bead blaster.


* Flat & phillips head screwdrivers, various sizes. JIS phillips-drive screwdrivers should be used.
* wire tube brushes, various sizes, for cleaning internal passages.
* brass & steel wire toothbrushes, for cleaning the outside surfaces.
* mini, mini-plus, or man-sized passage cleaning wires set.
* Engraving pen or punch to mark carb bodies, bowls, throttle shafts, etc. Ink won't do, even "sharpie" style permanent ink markers, since carb dip and spray cleaners will remove them.
* Hammer.
* METRIC open-end wrench and socket assortment
* pry bar or soft mallet.
* channel locks, vise grips, pliers---needlenose and otherwise.
* dental picks.
* mini drill bit for carb bowl starter jet cleaning.
* e-z outs and/or LH drill bits.
* small pencil torch or a heat gun.
* vise.
* drill & drill bits.
* float height ruler or gauge.
* fuel level sight tube.
* a 6" or 12" bubble level.
* a carb rack Alignment Plate, necessary as you re-assemble the individual carbs together and tighten the upper and lower rack bar screws. The four carbs must be placed on a perfectly flat surface as the screws are tightened or mis-alignment will occur, and life gets really un-fun if that occurs.........


* 100% silicone grease. Any petroleum-based grease will attack rubber.
* anti-seize fluid.
* semi-permanent (purple) thread locker fluid.
* brake or carb cleaner (and lots of it).
* carb dip or access to it.
* Fine sandpaper, automotive paint grade, 400-, 600-, 800-, 1000+ grit.
* restoration paints and coatings, if you are so inclined to do such detailing.


* synch sticks.
* YICS block-off tool, if your bike is has a YICS passage.
* YICS port passage cleaning tool, if your bike is has a YICS passage.
* gun brushes or similar.
* gun cleaner or similar.
* colortune plug.




PARTS NEEDED:

Carb rebuild:

* throttle shaft seals (if you split the carbs from the rack).
* fuel supply tube o-rings (if you split the carbs from the rack).
* float needle seat rebuild kit (seat, needle, clip, seat washer).
* bowl gaskets.
* idle mixture washers & o-rings, screws if damaged.
* jets, if damaged or incorrectly sized.
* carb bowl fuel drain screws.
* new replacement carb hardware (screws, etc.)---now is the time to upgrade to stainless steel and/or allen-head fasteners if so desired!




www.xjbikes.com/Forums...14692.html

Awesome! Thanks.

chacal, you forgot the two ton bottle jack, 5 gallon bucket with lid, impact gun, bikini clad helper and 2 cases of beer, white gloves and a lab coat, eye protection and a hard hat, lets do this right

and the fairy feathers !!!

they're in the mail, go ahead and get started, they'll arrive soon

that dang fairy shoulda got here already,she has wings ya know.....

Thanks guys!

Polock, you're right, and just make sure you don't get the beer or the bikini helpers at Harbor Freight.......

chacal wrote:

and just make sure you don't get the beer or the bikini helpers at Harbor Freight...

If they have a deeper voice than you do, RUN.

Good, solid advice there Schmuck!

As if the idea of pulling off cleaning, syncing, etc and reinstalling the carbs and praying the bike starts wasn't scary enough for someone who's never touched a carb...

The necessary parts/tools list is even scarier if on a near zero budget.

How necessary are:
* access to ultrasonic cleaner.
* access to tumbler or glass-bead blaster.

Would one of those $50 ultra sonic JEWELERY cleaners count and/or be big enough?

You don't need Ultrasound or a Tumbler.

You can get the job done with a minimum amount of tools and accessories.

Having Screwdrivers that fit the Pilot Mixture Jets and Fuel Jets is imperative.

A Bin with a rack to suspend the Carbs is also a luxury.
But, it helps to have the Rack suspended so that particulate getting sprayed-off ... drops-away and does not recontaminate the cleaning process.

Also, I'm not sold on the alignment jig... how much improvement do you get over a two (relatively beefy) rails that orient and fix the carbs in the two most critical planes? Does anyone swear by the alignment jig?