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Old February 17th, 2022, 10:32 AM   #201
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Originally Posted by ducatiman View Post
back on a set of especially nasty 250's today. Overtightened bowl screws needed dremel action to remove, as did all 8 brace screws. Badly discolored brass, clogged jets....yada yada. Completed pics to follow when completed.
Sounds like horror-movie of carbs!!! Post lots of photos in progress. I'll make video and set it to soundtrack! ...
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Old February 17th, 2022, 03:14 PM   #202
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sorry, the video production will need to wait for another set. Due to restricted time, I snapped NO before pics and just 3 afters. I'll post 1.

Of course I HAD to make time to drill out and tap a stripped carb top thread, using a 5mm thread bolt in place of the 4mm stocker.

Getting busy already, an EX500 in my garage for carb and valve clearance services. Sat for 4 years prior to a local student gaining ownership.
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Old February 18th, 2022, 11:19 AM   #203
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Quote:
Originally Posted by ducatiman View Post
sorry, the video production will need to wait for another set. Due to restricted time, I snapped NO before pics and just 3 afters. I'll post 1.

Of course I HAD to make time to drill out and tap a stripped carb top thread, using a 5mm thread bolt in place of the 4mm stocker.

Getting busy already, an EX500 in my garage for carb and valve clearance services. Sat for 4 years prior to a local student gaining ownership.
Sound like fun
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Old February 18th, 2022, 01:57 PM   #204
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doing a set of (4 years dormant) EX500's carbs today......here's visual documentation of some built up poop

given more time, this crap (varnish) would turn brown.
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File Type: jpg ow4.jpg (101.6 KB, 8 views)
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Old February 18th, 2022, 02:33 PM   #205
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Originally Posted by ducatiman View Post
doing a set of (4 years dormant) EX500's carbs today......here's visual documentation of some built up poop

given more time, this crap (varnish) would turn brown.
Look like you caught it just time that look like just after 1 year of just sitting around with Gas Stabilizer but will end it will turn in crystal state.

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Old February 20th, 2022, 11:40 AM   #206
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Now completed, slight improvement, IMHO. Bike in my possession, starting sequence to commence soon.
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Old February 20th, 2022, 07:14 PM   #207
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experimenting (within a deep learning curve) on my new injector cleaning/testing machine this evening
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Old March 7th, 2022, 04:34 PM   #208
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invested $35 in a set of used (complete) throttle bodies (strictly as spares) for my SS800 Ducati twin. Discovered 1 intermittent firing injector...no biggie I've got spares.

Well worth the investment, I believe.

During disassembly and split, I retained all settings. In the process of renewing fuel feed lines, requiring some special parts and attention.

Before/after pics.
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File Type: jpg inj14.jpg (106.2 KB, 2 views)
File Type: jpg inj15.jpg (87.0 KB, 2 views)
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Old March 20th, 2022, 02:11 PM   #209
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completed a REFURB of a set of BSDT38 Mikuni's off a Ducati 900SS/FE today, basically returning them back to stock spec.
Findings included: 150 mains (replaced with OEM supplied 140)
pilot screws backed out 5 (!) turns, returned to 3 1/2 (more normal starting point for Ducati spec)

As current owner is replacing airbox top with a stock unit, he found a basically removed (drilled/modded) cover upon purchase, the PO in an obvious search for "more fuel/more air".

Standard for these Mikunis, I found ovaled emulsion tubes (replaced with new). This condition is known to cause uncontrollable rich running.
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Old March 30th, 2022, 06:22 PM   #210
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a set of EX500 carbs completed today.
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Old March 31st, 2022, 05:25 PM   #211
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currently doing 250 ninj carb set & petcock refurbs.
(attached pic of completed, functional petcock, carbset to follow)

Petcock got 1 new mesh filter (upper), all new orings (was able to reuse diaphragm, with new, small oring installed o'course). It tested perfect as OFF seals, ON + RESERVE only flow when vacuum is actuated.

Rebuilding petcocks can be problematic, as such, testing PRIOR to installation is mandatory.
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Old March 31st, 2022, 05:53 PM   #212
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Quote:
Originally Posted by ducatiman View Post
currently doing 250 ninj carb set & petcock refurbs.
(attached pic of completed, functional petcock, carbset to follow)

Petcock got 1 new mesh filter (upper), all new orings (was able to reuse diaphragm, with new, small oring installed o'course). It tested perfect as OFF seals, ON + RESERVE only flow when vacuum is actuated.
Nice work
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Old March 31st, 2022, 06:01 PM   #213
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ty @shspvr
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Old April 1st, 2022, 10:45 AM   #214
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MOTM - Nov '18, Mar '17
pic as promised, carbset now refurbed.
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Old April 1st, 2022, 04:05 PM   #215
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today converted a standard 250 vac petcock to constant flow per client request.
Made a gasket, thus eliminating the diaphragms/gaskets and spacer, which leaked under testing. Also provided a missing oring at the lever.

ON-OFF-RESERVE still function as intended under constant flow condition. All good, no leaks.
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Old April 3rd, 2022, 09:22 AM   #216
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another set of Ducati / Mikuni BSDT38's in process. Fuel rail seals show a ton of white varnish, 1 pilot jet needed 'help' in removal. Thankfully, spares stocked for these exact circumstances. In addition, throttle slides frozen solid.
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Old April 3rd, 2022, 04:22 PM   #217
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finished them today....from this.....
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Old April 3rd, 2022, 04:25 PM   #218
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MOTM - Nov '18, Mar '17
to this

onward to 250's now in house
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Old April 4th, 2022, 05:20 PM   #219
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250's in house today. Finished, but not without some drama. Replaced aftermarket, non-marked main and pilot jets with factory stock sized jets. Ugh. Had no choice but to repair via enlargement/drilling/tapping a stripped female thread at the LH carb float bowl, upped from 4 to 5mm (see pic). Other changes were made where necessary to net a set of now perfectly set up, usable carbs.
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Old April 8th, 2022, 07:43 AM   #220
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another 250 set finished this morning. Coincidentally, the same exact drilling/tapping sequence in the same exact spot was required! Overtightening screws (compensating for flattened bowl gaskets) is a no-no. Replace the darn bowl gaskets! In this case, I ran out of my standard, I subbed Lite-Tek spares. Also replaced a torn diaphragm.
All consumables replaced, adjusted, synched, wet tested. I'll submit these as now fully functional, a far cry from what I was initially sent.
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Old April 30th, 2022, 12:21 PM   #221
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MOTM - Nov '18, Mar '17
refurbed, shipped back to owner yesterday.
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Old May 17th, 2022, 04:41 PM   #222
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busy day, 100 mile morning ride followed by completion of a 250 refurb upon return. They came out nice.
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Old May 23rd, 2022, 04:24 PM   #223
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another set of 250 carbs finished today after a quickie 45 mile morning ride.
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Old May 25th, 2022, 07:22 PM   #224
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a set from an EX500 done after another 45 miler today.
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Old June 4th, 2022, 06:21 AM   #225
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over a 12 hour period yesterday ....completed 2 refurbs , both a 250 and a 500.

The 250 a member here....I'm sure he'll be v happy.

The 500 my 2nd (of 3) sets for a group of converted sprint car guys in upper NY state. They insist on using Dynojet kits. OK, customer is always right. Comment after my 1st was run..."it never ran better" ...thus the repeat business.
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Old June 4th, 2022, 07:25 AM   #226
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OK, customer is always right. Comment after my 1st was run..."it never ran better" ...thus the repeat business.
I always took issue with that rule. A shrewd customer should rely on the expertise of the one hired to do the job. Otherwise, why hire them?
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Old June 20th, 2022, 04:29 PM   #227
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EX500's done today
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Old June 22nd, 2022, 04:10 PM   #228
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yet another 500 set done today.
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Old June 27th, 2022, 05:07 PM   #229
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MOTM - Nov '18, Mar '17
'81 Yamaha XV920 (early Hitachi CV) carbset done today.

A before/after or 2.
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File Type: jpg xv11.jpg (163.7 KB, 7 views)
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Old July 21st, 2022, 02:06 PM   #230
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doing a set of 250's today that were left as-is (loaded with fuel) in a bike parked for 7 years. Coming out perfect (will be bolt-on runners) using my normal cleaning tactics. Every part submerged within bowls was gross....jets totally clogged, discolored, floats were green, both float valves and slides were frozen in place.

I'll post a pic or 2 later, what a transformation!
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Old July 22nd, 2022, 11:24 AM   #231
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as promised
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Old July 27th, 2022, 03:57 PM   #232
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a REFURB on 250's underway today....needed to drill/eze-out a pilot screw with stripped head. Piece o' cake.
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Old July 28th, 2022, 01:32 PM   #233
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and.....finished. I'll project these'll bolt right up and run.
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Old August 11th, 2022, 06:10 PM   #234
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MOTM - Nov '18, Mar '17
and yet another 250 finished today. These featured "hogged out" pilot jets drilled so far out, biggest I've ever encountered...beyond .040". AND a float valve stuck in place ....yes, yet another.

In the end....all circuits clear, pilot jets replaced with OEM #38 from my stock, wet tested perfect. I'll submit yet another set of bolt-on runners were completed today.

I believe a PO was compensating for something in the drilling of the pilots....stock exhaust and airbox too! The bike then sat for 18 months before being sold to the current owner. Well, at least these little speedbumps keep me in "practice".
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Old August 11th, 2022, 06:52 PM   #235
Bob KellyIII
Retired motorcycle Mc.
 
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Name: Robert
Location: Weed, California.
Join Date: Jul 2021

Motorcycle(s): 2012 Kawasaki Ninja 250R, 2021 CSC TT250, 1977 Triumph Bonneville 750cc & 2021 CSC RX4 450cc

Posts: A lot.
Some people use the strangest reasoning for their actions....their reasonable to them at any rate but they just don't see the whole picture !
Nice work Gordon ! they look brand new !
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