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Old 09-05-2015, 12:36 PM   #1
pbfoot
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Carbs off Rebuild

Can anyone recommed a shop to clean the carbs on my 2006 Kawasaki Concours? Bike is a cali model. Carbs are out of bike. Was running fine Thursday night, but bike started missing below 4000 when I went to Reserve. Went to drain the bowls this morning and no fuel came out. Took a sample from the petcock and found rust particles in the fuel. Petcock is new. Cleaned tank out in July and again today. Not much rust came out today but removed a lot of rust in July. There was rust in the carbs when I flipped them upside down today. I would do it myself but would rather let a professional do their magic. Plan is to use an inline filter after I get the carbs back. I am the second owner, bike has 19k. Looks like the carbs have been off before I owned it. Caps for the pilot screws are missing. I also have t - fitting between carbs 1&2 and 3&4 that was not hooked up to anything. See photo.
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Old 09-05-2015, 01:33 PM   #2
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Ahh, was wondering why we didnt see you at renos. Hope you get her back up soon.
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Old 09-05-2015, 01:37 PM   #3
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Ahh, was wondering why we didnt see you at renos. Hope you get her back up soon.
Thanks. I know a guy in Florida who specailizes in Concours carbs. Was hoping for something close.
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Old 09-05-2015, 02:27 PM   #4
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A carb is a carb, regardless of what bike it's on. Just drop it off at Motorcycles Unlimited if you REALLY need someone to do the work for you.
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Old 09-05-2015, 03:10 PM   #5
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Quote:
Originally Posted by pbfoot View Post
I also have t - fitting between carbs 1&2 and 3&4 that was not hooked up to anything. See photo.
Those T-fittings look like the float bowl vents. Keeps the bowls at atmospheric pressure. Not normally hooked up to anything (some bikes have a bit of hose on them, but normally doesn't go anywhere).

Motorcycles Unlimited on 1960 does good work.
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Old 09-05-2015, 05:18 PM   #6
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Originally Posted by tankmonkey View Post
Those T-fittings look like the float bowl vents. Keeps the bowls at atmospheric pressure. Not normally hooked up to anything (some bikes have a bit of hose on them, but normally doesn't go anywhere).

Motorcycles Unlimited on 1960 does good work.
Thanks.
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Old 09-05-2015, 08:38 PM   #7
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If you have gotten as far as to take the carbs off the bike. Then you can just do a simple cleaning yourself! plenty of information on the webs on how to do it.
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Old 09-05-2015, 09:13 PM   #8
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If you have gotten as far as to take the carbs off the bike. Then you can just do a simple cleaning yourself! plenty of information on the webs on how to do it.
I guess that is what I will do tomorrow. Need to buy a new scewdriver. The float bowl screws are super tight. Don't want to strip the heads.
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Old 09-05-2015, 10:23 PM   #9
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Quote:
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I guess that is what I will do tomorrow. Need to buy a new scewdriver. The float bowl screws are super tight. Don't want to strip the heads.
screwdriver use-age tip: push and turn 65%push 35% turn. Also, depending on design and space allocation. You probably may be able to grab the float bowl screw head with a pair of GOOD pliers ie: knipex or vice grips and break the screws loose. this method is especially useful if it is a phillips head and they have been deformed (slightly stripped).
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Old 09-06-2015, 12:23 PM   #10
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They will not be Phillips. They look like Phillips but they're not.
They are called, JIS screws. Get the right screwdriver and you'll be less likely to strip them.

THAT'S the reason bike screws seem to strip so easy.

Read this. ...

http://www.webbikeworld.com/motorcyc...-screwdrivers/
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Old 09-06-2015, 01:49 PM   #11
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Quote:
Originally Posted by bumblebee View Post
They will not be Phillips. They look like Phillips but they're not.
They are called, JIS screws. Get the right screwdriver and you'll be less likely to strip them.

THAT'S the reason bike screws seem to strip so easy.

Read this. ...

http://www.webbikeworld.com/motorcyc...-screwdrivers/
Cool. That makes perfect sense. Thanks for the information.
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Old 09-06-2015, 01:58 PM   #12
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Quote:
Originally Posted by bumblebee View Post
They will not be Phillips. They look like Phillips but they're not.
They are called, JIS screws. Get the right screwdriver and you'll be less likely to strip them.

THAT'S the reason bike screws seem to strip so easy.

Read this. ...

http://www.webbikeworld.com/motorcyc...-screwdrivers/
Can I grind the radius off the webs of a Phillips screwdriver?
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Old 09-06-2015, 03:19 PM   #13
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Quote:
Originally Posted by bumblebee View Post
They will not be Phillips. They look like Phillips but they're not.
They are called, JIS screws. Get the right screwdriver and you'll be less likely to strip them.

THAT'S the reason bike screws seem to strip so easy.

Read this. ...

http://www.webbikeworld.com/motorcyc...-screwdrivers/
Looks like the tip on a JIS screwdriver is at a 57 degree angle as well as having no radius at the web. I ordered a set off of amazon. I can wait until Wednesday. Thanks again.
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Old 09-06-2015, 03:28 PM   #14
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Quote:
Originally Posted by tankmonkey View Post
Those T-fittings look like the float bowl vents. Keeps the bowls at atmospheric pressure. Not normally hooked up to anything (some bikes have a bit of hose on them, but normally doesn't go anywhere).

Motorcycles Unlimited on 1960 does good work.
On a Kawi with ram induction, they go to the small ram tube to pressurize the float bowls. Otherwise, the air pressure from the main ram induction pushes the fuel away from the mains and leans it out. Forgot to connect mine back up one day and it felt like a bad fuel pump. Re-wired the pump, tested, re-wired, tested, before I noticed the tube not connected.

.. and also have an extra fuel pump that I ordered on eBay before I found the problem.
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Old 09-06-2015, 03:35 PM   #15
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Here's a photo of mine
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Old 09-06-2015, 08:36 PM   #16
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Make sure you get a Pro . Ask for pictures via smart phone . Most shops now dont know what a carb is . Last customer was told he needed new carbs for his yamaha V Star 1100 . He did not need new carbs . These are ZRX carb just like yours . Make sure they split the bank / install all new O Rings .

20150906 203103 zpshstcttzk
20150906 203138 zpsscborfk4
20150906 203144 zpsabasxpdr
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Old 09-12-2015, 09:26 AM   #17
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Quote:
Originally Posted by bumblebee View Post
They will not be Phillips. They look like Phillips but they're not.
They are called, JIS screws. Get the right screwdriver and you'll be less likely to strip them.

THAT'S the reason bike screws seem to strip so easy.

Read this. ...

http://www.webbikeworld.com/motorcyc...-screwdrivers/
Used my new JIS screwdrivers today. Bowl screws came right off except for the two that I stripped. I turned them into flat heads with my Dremel and got them off as well. Thanks so much for the tip.
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Old 09-12-2015, 11:34 AM   #18
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I'm a little late to the thread, but here's another tip!!

Before I start removing the screws, I put the screwdriver in the slot and tap the handle with a hammer. This helps the screwdriver get a good bite on the screw head, especially if they are a little messed up from a previous attempt/repair. If it's chewed up really bad, I'll even tap the head of the screw directly with a hammer and it flattens out the screw head a little. Stick the screwdriver back on and hit it with the hammer on the head of the screwdriver. It pushes the screwdriver in nicely and reshapes it to have a good grip again. I've also had very good luck using impact screwdrivers. Like this one http://www.harborfreight.com/impact-...ase-37530.html

Sounds like an easy clean. No need to take the carbs off the rails, you will just end up killing yourself trying to re-sync the carbs without the right tools. If it was running fine before, it's just some debris clogging the jets. Clean everything up and blow out orifices with compressed air. If you remove the needle screws, be sure and put them back the way you found them. In other words, if it was 2 turns out, make sure it goes back 2 turns out. If you remove the floats and float needles, make sure they go back in the same carb with the same parts, otherwise the heights might come out different and you will need to adjust them. Or, if you have the right tool, just measure them all and put back to recommended height. Don't get any cleaner on the diaphragms or the rubber could expand/contract and not work correctly either. Other than that, it should be pretty straight forward to clean them.

Good luck getting back on the road!!
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Old 09-12-2015, 12:37 PM   #19
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Quote:
Originally Posted by signpimp View Post
I'm a little late to the thread, but here's another tip!!

Before I start removing the screws, I put the screwdriver in the slot and tap the handle with a hammer. This helps the screwdriver get a good bite on the screw head, especially if they are a little messed up from a previous attempt/repair. If it's chewed up really bad, I'll even tap the head of the screw directly with a hammer and it flattens out the screw head a little. Stick the screwdriver back on and hit it with the hammer on the head of the screwdriver. It pushes the screwdriver in nicely and reshapes it to have a good grip again. I've also had very good luck using impact screwdrivers. Like this one http://www.harborfreight.com/impact-...ase-37530.html

Sounds like an easy clean. No need to take the carbs off the rails, you will just end up killing yourself trying to re-sync the carbs without the right tools. If it was running fine before, it's just some debris clogging the jets. Clean everything up and blow out orifices with compressed air. If you remove the needle screws, be sure and put them back the way you found them. In other words, if it was 2 turns out, make sure it goes back 2 turns out. If you remove the floats and float needles, make sure they go back in the same carb with the same parts, otherwise the heights might come out different and you will need to adjust them. Or, if you have the right tool, just measure them all and put back to recommended height. Don't get any cleaner on the diaphragms or the rubber could expand/contract and not work correctly either. Other than that, it should be pretty straight forward to clean them.

Good luck getting back on the road!!
Thanks for the reply.
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Old 09-12-2015, 06:05 PM   #20
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Quote:
Originally Posted by c10 View Post
Make sure you get a Pro . Ask for pictures via smart phone . Most shops now dont know what a carb is . Last customer was told he needed new carbs for his yamaha V Star 1100 . He did not need new carbs . These are ZRX carb just like yours . Make sure they split the bank / install all new O Rings .

20150906 203103 zpshstcttzk
20150906 203138 zpsscborfk4
20150906 203144 zpsabasxpdr
Carbs are cleaned. Bike runs great. Thanks for all of the help.
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