82 XJ carb question

[DavePlum]

I'm in the process of disassembling some carbs from a 82XJ (going to clean them) and not having any luck removing two of the pilot screws (#1 & #4). They both will turn out a full turn and then just won't budge after that. The two pilot screws on #2 & 3 came out easily. I should also add that when I'm turning the two stuck ones out I can hear the spring making a popping sound the last 1/4 turn before they come to their abrupt stop. Is this a common problem and does anyone have any suggestions how I might try to get these last two out? Thanks

[TopCatGr58]

Dave,

The Pilot screws on the later carbs, 81-82 are not as fine tipped and are not prone to getting stuck in the carbs. They DO use an o-ring and small metal washer, and so combined with that, and possible corrosion if they were left out exposed to rain/etc., may have formed some serious galvanic corrosion down in the pilot jet tunnel.

The jet tunnel has an opening directly under it on the upper side of the carb throat, and so you could possibly squirt some carb cleaner/penetrating fluid/PB Blaster up into that port to try to help dissolve the corrosion. The little metal washer may be pushed up onto the end of the pilot screw and that may be what's stopping it from unscrewing all the way out??

T.C.

[Radioguylogs]

Plug debris?

My last project was the first time I worked on the newer (>80MY) MKII carbs.

The PO had tried to remove the brass plugs that cover the idle mixture screws. On a couple of them, he didn't succeed and left a brass collar inside the tower that caused the idle screws to behave just like yours.

I wasn't familiar with those brass plugs, so I was really glad I stopped and studied before I really bugered up the carb bodies.

If you think this might your problem, I used a fat screw on one carb and an Easy-out the other... whatever seems to grab that 'collar'.

Good luck, whatever you find.

[motoman]

For those tin caps covering mixture screws, carefully drill a small hole through the cap, thread in a sheet metal screw, using a small pair of vise-grips with the adjuster thumb screw replaced with short thickwall piece of metal slid over a long bolt and thread it back into veice grips. Snap vice grips on already inserted screw and use it as a miniature slide hammer. Immediately will pop the seal caps out.

[motoman]

BTW DavePlum, if those mixture screw caps are in fact brass and not just tin inserts, tells me someone used just whatever to cap those locations. Originally, they came from factory with just tin inserts, and back in the day ALL Yamaha dealerships had a supply of them for their shop personnel. They are, and have been NA from dealers for a decade or more now, as they are not necessary. They were just inserted in those locations to keep fingers like ours out of and off the carbs.

If the idle mixture screws, once removed are missing the teeny thrust washer and O-ring, they are available from Suzuki manufacturing.
Suzuki part number for O-ring: 13295-29900
Suzuki part number for teeny thrust washer: 99040A316
(Suzuki GS1100 used same Mikuni,same millimeter Mikuni carbs).

[DavePlum]

Thanks for the replies, I much appreciate everyone taking the time to post and offer suggestions and helpful info. Being a novice to working on carbs I need all the help I can get, it's a learn as I go exercise.
As an update, I tried carb cleaner last night which seemed to help to the tune of an extra 1/4 turn out. Today I got out the dremel and ground down the sides of a screwdriver so it would fit in the tunnel, it had a wider tip that would fit a bit more snug in the slot of the pilot screw. Didn't really help like I had hoped, all it really got me was the need to purchase another grinding stone. I really didn't want to try and use an easy out on the two that were stuck and didn't have one small enough anyways. I ended up going to a shop and the guys there got them out (with a easy out) while I waited. Cost me a Jackson but to me it was worth it.
On a side note, only one of the four pilot screws had that tiny "o" ring.
Motoman...none of the four carbs had pilot screw caps, perhaps I didn't explain it very well...I am a noob when it comes to working on carbs and a lot of the parts I have to look at my shop manual just to know what to call them...lol
btw... these are 82XJ carbs that will eventually go into my 80SG project (hopefully)
Again, my thanks to everyone that responded.

[DavePlum]

Ok, I'm preparing to reassemble these carbs after cleaning and have a couple questions.

1 Does it matter the orientation of the needle jet as it hangs from the tang of the float? When I disassembled I didn't pay close enough attention to notice and I thought I read (or heard) it does matter.

2. During disassembly one of the pilot jets didn't survive. Where's a good source for replacement? Can the O-rings on the pilot jets be purchased without having to buy the entire assembly? (needle, spring, washer, o-ring)

Thanks

[motoman]

Ok, I'm preparing to reassemble these carbs after cleaning and have a couple questions.

1 Does it matter the orientation of the needle jet as it hangs from the tang of the float? When I disassembled I didn't pay close enough attention to notice and I thought I read (or heard) it does matter.

2. During disassembly one of the pilot jets didn't survive. Where's a good source for replacement? Can the O-rings on the pilot jets be purchased without having to buy the entire assembly? (needle, spring, washer, o-ring)

Thanks

1.......No
2........Re-read my #5 post.

[DavePlum]

Thanks, sorry I had forgotten you posted that info about the O-rings and washers. In my last post I typed pilot jet but I meant to type pilot screw, that's the item I'm really looking for. I don't even see it in the parts illustration or parts list on partzilla.

[motoman]

Thanks, sorry I had forgotten you posted that info about the O-rings and washers. In my last post I typed pilot jet but I meant to type pilot screw, that's the item I'm really looking for. I don't even see it in the parts illustration or parts list on partzilla.

Same,same.