Carbs Flooding the airbox & more!

[motoman]

Sorry bout' any confusion Gunny. My final words were in reference to float bowl screws.

[GUNNY1966]

Sorry bout' any confusion Gunny. My final words were in reference to float bowl screws.

Don't worry about it, no problems here!!

[GUNNY1966]

So I tore down the carbs to find they needed a bath & not a shower, imagine that! I got them SPOTLESS!! I'll post more pics & such when I get a chance, I've been working 70 hr. work weeks & I'm all washed up!! See Me later :-)

[GUNNY1966]

So as I said I tore down the carbs & they seriously needed a bath!!

As you can see in the pic the needle valve O-rings were severely decayed & I figured out then that this is what was causing the fuel to flood into the air box. I spent hours cleaning these so they would be spotless. Here's a few pics & I have placed some definitions within the pics so one can read & view the pics.

Carbs:

Needle Valve O-Ring:
further described:

This is a pic of just 2 carbs back flushed to remove the trash from the carbs:


I also found 2 bad diaphragm's in the disassembling of the carbs. This just added to the cost & I wasn't anticipating this but it happens:


Needle Valve inserts:

Diaphragm's were removed first thing:


PART NUMBERS FOR DIAPHRAGM'S for a 1982 Yamaha XJ1100:


Checking the float level:


It does NO GOOD to simply do all this work without cleaning out the fuel tank! Even tho the petcocks have filter screens, I took the time to clean the tank. Everyone seems to think that this is expensive & a not so much value added step however it's SIMPLE!!!
( 1 ) Simply drain all the gas from the tank then remove both petcocks.
( 2 ) Remove any trapped gas by sloshing the tank around.
( 3 ) REMOVE THE FILTER SCREENS from the petcocks.
( 4 ) Reinstall the petcocks without the filter screens.
( 5 ) Fill the tank completely full of DISTILLED WHITE VINEGAR ( this only cost me $16.00 USD ).
NOTE: Be sure to try to keep the vinegar off your paint!
( 6 ) Allow the tank to sit in direct sunlight for a minimum of 2 days, this will allow the vinegar to react with some level of heat & it will remove almost all the rust your tank has in it as well as any dirt grit grime ect. ect..
( 7 ) After it has sat, remove the petcocks & fill it with WATER then slosh it around VIGEROUSLY!
( 8 ) Fill it with water then flush it NUMEROUS TIMES to help remove any & or all impurities!
( 9 ) Once it has been flushed COMPLETELY, place 2 gallons of gas in it slosh it around VIGEROUSLY then allow the fuel to drain out. REPEAT THIS STEPS UNTIL THE GAS IS CLEAN!!
( 10 ) Be certain the water has been dispersed from the tank with the gasoline. I repeated this step 3 times to be certain there was NO WATER or VINEGAR & the tank was as clean as I could get it.
( 11 ) Clean the petcock screens & the petcocks. Cleaning the petcocks is also advised so there is not issue's.
( 12 ) Reinstall the petcocks & screens!!

Pic of fuel tank inside now:
[img]https://gyazo.com/974e6c13dc26d5a5ec1fd68d3393fa11.jpg[img]

Completing the cleaning of the fuel tank is a must regardless in my opinion however others may view this differently. My tank had obviously never been flushed therefore it was EXTREMELY FILTHY!!

I added 2 in-line fuel filters in which some will say this isn't necessary but it's personal preference. I also replaced ALL the fuel lines & clamps so there are NO LEAKS whatsoever!

In Line Fuel Filters:

In Line Fuel Filters:


I went to great length's to be certain that the float level's & everything was PRECISE therefore eliminating any further issue's. I replaced every o-ring & cleaned every little thing. It wasn't that hard & the only trouble I had was getting the carbs all synced back together on the rail. Once I got them all reassembled I knew the bike would perform 100% better than it did when I first bought it. As soon as I get everything else put back together I will post a video of it running. I also replaced ALL the fuel lines & added IN LINE FUEL FILTER on top of those which are in the tank petcocks. I wanted a added level of protection. I placed O-rings on the filters so they wouldn't be rubbing against the air cleaner box or the carbs for that matter. As you can see in the pics they have a glass insert so I wanted to be certain they wouldn't vibrate against the air box or carb & break.

Now I'm gonna post a video of it running when I get a chance so STAY TUNED!

[3Phase]

That's some nice work there, Gunny, oosha!

[GUNNY1966]

that's some nice work there, gunny, oosha!

Thank You Sir!

[TopCatGr58]

Hey Gunny,

Awesome work, but was a little bit of extra work to have to click on each photo to view them. I followed the first one to your hosting website. Then I right clicked the photo and copied the LOCATION information/link. I then pasted it into a NOTEPAD doc so I could review it, the two things missing for your posted links were that you were using the URL tags....which you may or may not have even done intentionally....if you just posted your photos URLs as plain text into your post...our site's software will create active links but will make the WEB page links with URL tags, not Image links with IMG tags.

The other thing is that your links were missing the .jpg ending that makes it a complete 3rd party/site hosting link that will allow the photos to show directly in the POST on our site.

I edited your post to reflect those changes, and now the photos are viewable WITHIN the thread. Not sure how you're getting the links to your photos, if you're highlighting and copying the Browser's Address from the window, that could be why they are missing the .jpg part. Just some FYI's. Carry on!

T.C.