Broken Carb insert.

[WorkingProject]

Hey guys.  I have been trolling these forums for about a week now, and it has some GREAT information on it.  You all have really helped me out of some binds during my carb. rebuild.  I have never done this before or even owned a car with a Carburetor before.  So I am in uncharted water with what I am doing (which makes it fun.).  

So looking at a few older posts and some nice write-ups from you all on here has really helped, but I have run into some problems that seem to be unique to, well, just me.  

So I picked up a 97 GS500 about a week ago.  It was running bad, and had ZERO low end.  So I took off the gas tank/seat, and noticed that the cable to my manual choke was frozen open!  So the sliders in my carb were stuck down.  Well, that explains the breathing problem.  So I had to cut the cable (ordered a used one from an 04 off Ebay).  

After I cut the cable.  I tired to start the bike again.  I pushed the choke bracket in (closed the sliders) and the bike started just fine.  After I got it warm.  I let go of the bracket and the bike died on me.  So I started it back up, and tried to warm it up again.  I did this about 4 times and still it would not idle.  I decided to take of the carbs off and clean them.  

Once I got everything off the bike.  I started spraying the carbs down with carb cleaner.  The color of junk that came out looked like pretty brown, so I decided just to take apart the whole assembly get new seats,floats, gaskets and clean it real well.  

The whole process was quite simple (seemingly) until I took out one of my slider guides that hold the "Emulsion" tubes.  Check this out....



I know this isn't a good thing, because it was broken before I got it.  You could see where someone had put some type of glue or something in the hole to hold the broken piece down.  At first I thought, ok...no big deal.  I will just find a new one (or used one)....That is next to impossible.  They don't even make this piece, you have to order a whole new carb.  This is unsettling to say the least.  My project is now looking like it might be more than I prepared for.  So I just decided to glue it back with some super glue.  I build model cars for fun, and had plenty of things to help with this process.  It turned out nicely and it's well sealed.  So I hope it holds out for me.  (so problem solved, i hope).

My next possible "problem" with the bike.  I was thinking about re-jetting the bike because it came with the K&N Lunch box filter on it.  Well.  I took off the float bowls and noticed the main Jet said 140 on it.  I have never done this before, so I am guessing this is a 140 jet, meaning it has already been re-jetted, right?



While I had everything off I decided to take off the spark plugs, and this is where things were strange.  I took off the right plug (sitting on the bike facing forward) and it had a nice whiteish tip on it.  The left side was covered in fuel and fouled out like crazy!  I mean this thing was BLACK!  So now I know it was some sort of carb problem.

I sprayed everything really well with carb cleaner, took out the main jets, but left the others inside.  (so i am not sure what the other jet is set at, guessing a 40 or 50).  Sprayed it down with WD40 and got some of the corrosion off of it, then rinsed it with DAWN/Water mix and flushed it out with tap water.  I'll lube everything once my rebuild kit gets here and put it all back together.  

So I guess my question is, what else should I do while I am here at this point.  The bike has signs of being tampered with, and mismatch screws in places...so I know someone has messed with it.  It has 16000 miles on it.  So it has plenty of life left on her.  She just needs some love.

Thanks
-Cody

[Paulcet]

Yeah, that slider guide is not supposed to come out.  No harm in gluing it back together, it can't get worse really.  I would suggest you replace o-rings while you're in there.

[WorkingProject]

I am.  I would think the rebuild kit comes with it, right?  Sorry for the newb questions, but I just assumed that a carb rebuild kit, came with everything to rebuild one. lol

[JAY W]

Hi,check float heights whilst your in there and pay special attention to the smaller air jets (use a screwdriver that fits well as the heads round easy) and remove mixture screws with springs and very small o`ring and clean airway.Then junk the screws that hold the bowls on and fit allen bolts.

[WorkingProject]

Thanks man. That is something I would have never thought about.