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Leaking fuel rail=unexpected carb rebuild...

Discussion in 'XJ Technical Chat' started by jammer41, Apr 13, 2010.

  1. jammer41

    jammer41 Member

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    So my fuel rail is leaking and since I will have to break them apart I might as well rebuild them also.

    So the question is what parts do I need? (tools/solvents, etc... aside) Obviously a set of fuel rail o rings but what other rings/gaskets do I need to order from chocal? I didn't see a "carb PM/rebuild kit" of sorts.

    **edit**
    I guess I am looking for the obvious most common parts to order for a basic rebuild the bike runs great (other than a sticky idle, hangs at 3k after highway riding, sounds like a clunk test fail to me) as is but since they will be out and broken apart...
     
    jammer41, Apr 13, 2010
    #1
  2. Alchai

    Alchai Member

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    These might help!
    Carb Cleaning:
    http://xjbikes.com/Forums/viewtopic/t=2 ... n+own.html
    More Carb Cleaning "Your carbs need to go CLUNK":
    http://xjbikes.com/Forums/viewtopic/t=1 ... aning.html
    Bench Syncing:
    http://xjbikes.com/Forums/viewtopic/t=6 ... carbs.html


    As far as what parts -- look on the parts forum here. Chacal is very detailed on what you will need to do it right.

    All in all - full rebuild? -- New gaskets, new v-seals on the throttle shaft, new o rings on the fuel shaft, new springs if needed (piston spring and pilot screw spring for each carb..inspect these, they aren't designed to wear out) washers for the pilot screws, orings for the pilot screws...check your floats, inspect your fuel pins attached to the floats...

    ..Seriously.. read chacal's section for to buy the parts...
     
    Alchai, Apr 13, 2010
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  3. schmuckaholic

    schmuckaholic Well-Known Member

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    Oh, Len... idea for you...

    Oh, lessee, off the top of my head and borrowing from Alchai's post:

    Bowl gaskets
    o-rings for the fuel rail
    throttle shaft seals
    float needles

    ...that's pretty much it, really, as far as gaskets and such go. As far as how to replace the throttle shaft seals, this might help. Bonus: covers the fuel rail o-rings at the same time.
     
    schmuckaholic, Apr 13, 2010
    #3
  4. jammer41

    jammer41 Member

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    So I went through the carb section in chacals catalog and here is what I came up with:

    HCP38BSET8 Aftermarket Hitachi throttle shaft V-SEALS, set of 8
    HCP2561SET8 aftermarket Hitachi butterfly valve retaining SCREWS
    HCP895SET4 Aftermarket Hitachi idle mixture screw O-RINGS, set of 4
    HCP896SET4 Aftermarket Hitachi idle mixture screw spring seat WASHERS, set of 4
    HCP2420SET10 Aftermarket Hitachi Viton material fuel supply tube O-RINGS, set of 10
    HCP50SET4 OEM Hitachi carb BOWL GASKETS, set of 4
    HCP872SET4 Aftermarket Hitachi FLOAT NEEDLE VALVE ASSEMBLIES, set of 4
    HCP8540 Aftermarket carb diaphram rubber RnR FLUID

    My XJ is now my primary transportation so it cant be out of service for more than a day or two so I am just trying to cover my bases as to what I will need to order before I delve into the rebuild.
     
    jammer41, Apr 14, 2010
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  5. Alchai

    Alchai Member

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    Only need 6 of the HCP2420, two between each carb

    []12[]34[]56[]
     
    Alchai, Apr 14, 2010
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  6. jammer41

    jammer41 Member

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    Well the rebuild went well. The carb float adjustment, not so much. Tried wet with gas and after five or six tries I was fed up, went to grainger and bought a pocket rule and set them dry to the 17.5mm and some minor tweaks later all done.

    Also I built a set of sync gauges (again from granger) balanced, plug chopped a few times and then...

    DEAR GOD!!! Idle no longer hangs after highway riding (used to hang at 3k for a good ten min of surface street speeds), the entire power band is so much longer and stronger. Now I am wondering about the clutches... They slip at 7.5k on WOT.


    Thanks to those who helped in the process and all of you out there contributing info to the site!
     
    jammer41, Apr 23, 2010
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  7. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    First clue on the clutch will be the mileage on the bike... ??
     
    bigfitz52, Apr 24, 2010
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  8. jammer41

    jammer41 Member

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    Just about to turn 19k. After some riding today, The clutches seem to be ok for all intensive purposes. They do however slip when pulling hard at 7.5k rpm in fifth. Any other time its fine. So I am thinking that it will be a winter project. (I am leaving next month for a 4 month trip so the bike has the summer off)
     
    jammer41, Apr 24, 2010
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