Throttle shaft reassembly

Howdy gang - getting my carbs back together now that I've got all the parts I need (Thanks chacal!).

Specifically I'm having troubles with the throttle shafts, and trying to determine what order the parts go in.

Here is carb 2's shaft with a spacer bushing. What side of the carb body does the bushing go onto? My assumption is that it goes between the 2/3 carb under the spring - left side as pictured...right? Also, where does the plastic washer go?


Next is carb 3 - same issue, where does the (slightly thicker) spacer bushing go in relation to the carb body? I also have a plastic washer for this carby as well...



Now with shafts 1 and 4, there are no metal spacer bushings, so I've got the parts order figured out pretty easily, but there is a bit of lateral play on the shaft - the plastic spacer bushing does not seem to quite fill the space before the e-clip on the far outside of the shaft ends...


Is this because I don't have my butterflies in yet, or should I buy new plastic washers to fill the space between carb body and e-clip?

While we're at it, how many turns out do my idle mixture screws need to be?

Anything else I should know about carb reassembly?
Clunk test is golden, and all rubber bits are new besides slide diaphragms.

 

I don't have access here but go to bike bandit or somewhere else and pull up the carbs....those places are a great reference for parts assemblies


good luck,

jeff

 

The thin plastic shim washers always go on the opposite side of where the recoil spring is located (on Mikuni carbs only; Hitachi carbs use the shim washers on both sides of the shaft).

Here's the 550 Mikuni assembly reference; "inner" refers towards the centerline of the bike. Notice that all four carbs use their own unique recoil spring........


HCP13624
OEM Mikuni grooved THROTTLE SHAFT #1 carb
7.92mm diameter

Outer
E-clip: HCP6836
Plastic washer: HCP6837
Shaft v-seal: HCP6838B
Butterfly Valve on shaft: HCP5492
Butterfly Valve screws: HCP5898
Shaft v-seal: HCP6838B
Return spring: HCP13628
Inner




HCP13625
OEM Mikuni threaded throttle SHAFT #2 carb
7.92mm diameter

Outer
Nut: HCP13681
Thin alum. tab-ear lockwasher: HCP13685
Bracket arm (removable): HCP13679
Plastic washer: HCP6837
Shaft v-seal: HCP6838B
Butterfly Valve on shaft: HCP5492
Butterfly Valve screws: HCP5898
Shaft v-seal: HCP6838B
Thin alum. spacer: HCP13686
Return spring: HCP13629
Inner





HCP13626
OEM Mikuni threaded throttle SHAFT #3 carb
7.92mm diameter

Outer
Plastic washer: HCP6837
Shaft v-seal: HCP6838B
Butterfly Valve on shaft: HCP5492
Butterfly Valve screws: HCP5898
Shaft v-seal: HCP6838B
Thick alum. spacer: HCP13687
Throttle cable quadrant: HCP13680
Return spring: HCP13630
Lockwasher: HCP13682
Nut: HCP13681
Inner





HCP13627
OEM Mikuni grooved THROTTLE SHAFT #4 carb
7.92mm diameter

Outer
E-clip HCP6836
Plastic washer: HCP6837
Shaft v-seal: HCP6838B
Butterfly Valve on shaft: HCP5492
Butterfly Valve screws: HCP5898
Shaft v-seal: HCP6838B
Return spring: HCP13631
Inner

 

After a bunch of head scratching and playing with the parts, I have everything back in order.

However, when I look at the butterfly valves themselves, there is a little bit of light coming through at the bottoms. How can I solve this issue?

I think the edge of one of the valves is a bit chewed up so it doesn't seat as it should.