Broken Carb Float Post Fix!!

[Winterhawk]

Wow, what a fix. I've been drilling a tiny hole in the post and using saftey wire to secure the float pin.

[Toolmaker Tim]

Broken post fix

I have come up with a fix for those with acess to a mill.You need to get a 1/4 stripper bolt from a machinery supply company like J&L or MSC. You need a stripper bolt with about a 1" body.
1st- strip the carb down to the body
2nd- set up the carb with the posts facing up. Use an indicator to pick up the center of the post bottom.
3rd- mill the remaining post down to the point were it changes from a casting to a machined surface.
4th- drill and tap the post for a #10-24 thread. Make sure when you chamfer the hole prior to tapping, that the chamfer diameter is no larger than the diameter of the tap.
5th- clean the hole out with a good degreaser or carb cleaner. Make sure your stripper bolt will screw in far enough to bottom out on the milled surface that you drilled and tapped.
6th-Put a fuel resistant thread locker or epoxy on the threads to hold them in place. Or you can drill a correct sized hole in the side of the lower part of the float post and push a roll pin in thru the post and stripper bolt.
7th- cut off the head of the stripper bolt so it is the same height as the surviving post. Mill or file the sides of the bolt body so the float will fit between the old post and the new one.
8th- Turn the carb so the pin hole on the remaining post is vertical and on the top. Line up the hole, indicating center is best, and use a drill that will fit through the remaining pin hole (I believe it is .099 diameter, but I am going by memory, you are better off checking with a pin gage) and drill thru the bolt body. Make sure it is a sharp cobalt drill meant for cutting steel and make sure it is long enough to go through the original hole and the new post. Use cutting oil ! and about 600-700 RPMs. Make sure the drill cuts and doesn't work harden.

I haven't ever posted pictures, but I will see if I can get one of my kids to help me with that I have a extra carb set I was thinking of doing this to all of the posts.

[Toolmaker Tim]

Sorry

Sorry Steve, I didn't mean to hijack your thread. Yours looks like a great fix if you dont have acess to machinery. I just put mine out there for anyone that might have a post broken off flush with the lower part of the post.

[xj11john]

Thanks for the reply steve, upon closer examination the P.O. had a hole drilled and I guess the wire came off, so I just used a paper clip for wire and twisted it up real good, its in place and nice and sturdy now.

[xj11john]

Alitte off subject, would anyone know the correct float hieght for an 82 xj750 in MM or inches, I dont have the clear tube to do that test, thanks in advance.