I have a 2001 GS 500 and I have been looking for some pictures of where the pilot adjustment screw is.  I been reading that it is behind the brass plug but I am afraid to drill it out.  There is a small pin hole in that brass plug so I didn't want to drill out something that should not be drilled out.  Does anybody have a pictures of a 2001 carb that shows exactly where the plug is?  There are 2 brass plug, 1 big with no pin hole and 1 small with a pin hole.

Also, where do I place the #4 washer to shim the carb?  Is is directly under the 2 caps?  I've read that you do the needle itself behind the "C" clip but I can't get the needle out.  Any ideas on this?

Quote from: zman93 on June 18, 2008, 11:08:51 AM
I have a 2001 GS 500 and I have been looking for some pictures of where the pilot adjustment screw is.  I been reading that it is behind the brass plug but I am afraid to drill it out.  There is a small pin hole in that brass plug so I didn't want to drill out something that should not be drilled out.  Does anybody have a pictures of a 2001 carb that shows exactly where the plug is?  There are 2 brass plug, 1 big with no pin hole and 1 small with a pin hole.

Also, where do I place the #4 washer to shim the carb?  Is is directly under the 2 caps?  I've read that you do the needle itself behind the "C" clip but I can't get the needle out.  Any ideas on this?

i don't have one of the 3 circuit carbs, can't help you with the brass plug question on THAT model bike. sorry.

as far as shimming the needles:

remove the plastic caps from the carbs (two screws)...

don't loose the O-ring on top of the now cover-less carb !

lift up gently on the rubber boot, the needle will raise with it, along with a c-clip, a plastic guide, and the lower plastic guide.

remove the guides from the needle, put the #4 washer under the c-clip

put the large plastic guide on below the #4 washer, then the smaller plastic guide. make sure they move easily on the needle.

drop the needle into the slide/boot assembly and make sure it all moves easily.

put a screwdriver into the assembly (light pressure!) to keep the needle centered in the slide tube (carburator) and make sure it seats in the carb center.

replace the o-ring (still got it !?) and the vacuum cap.

ride

This thread has a picture and some discussion (read the discussion because the picture label is not correct):
http://gstwins.com/gsboard/index.php?topic=40523.0

When I remove the cap, the rubber boot and needle come up in one piece.  The needle will go up and down but that's it.  There is a small hole on top where you can grip  a small piece of flat sided plastic with needle nose pliers.  I pulled on it but it would not come off.  Is this the plastic guide you are refering to?  Is it hard to come off?

-Zhi


i don't have one of the 3 circuit carbs, can't help you with the brass plug question on THAT model bike. sorry.

as far as shimming the needles:

remove the plastic caps from the carbs (two screws)...

don't loose the O-ring on top of the now cover-less carb !

lift up gently on the rubber boot, the needle will raise with it, along with a c-clip, a plastic guide, and the lower plastic guide.

remove the guides from the needle, put the #4 washer under the c-clip

put the large plastic guide on below the #4 washer, then the smaller plastic guide. make sure they move easily on the needle.

drop the needle into the slide/boot assembly and make sure it all moves easily.

put a screwdriver into the assembly (light pressure!) to keep the needle centered in the slide tube (carburator) and make sure it seats in the carb center.

replace the o-ring (still got it !?) and the vacuum cap.

ride
[/quote]

Quote from: beRto on June 18, 2008, 12:34:13 PM
This thread has a picture and some discussion (read the discussion because the picture label is not correct):
http://gstwins.com/gsboard/index.php?topic=40523.0

My carb looks similar but where the purple and red arrow are, however there is a flush brass plug with a small pin hole in the center (about the size of a small paper clip).  Could this be considered the "air jet (160)"? The one in the back in green arrow looks the same (size, location and dimple in middle)

I'm just afraid to drill it out and there is no screw under it then I'm screwed(literally)

sorry...don't know how to post pictures.

Send it to me ... over 200 carbs with prolly 100 drillings ... BTW I have had to drill out bolts, air screws themselves not just the caps, pilot jets and on 2 ocassions the air jets ...
I have also drilled out butterflies and split carbs off the racks and on more than 1 ocassion fabbed up some stuff inside a carb. My seca carb needed to get a hollow bolt, I decided a mikuni mainjet with hollowed out insides was the ticket. Yea yea, I know carbs. So send em.
Cool.
Buddha.

Quote from: The Buddha on June 18, 2008, 07:04:38 PM
Send it to me ... over 200 carbs with prolly 100 drillings ... BTW I have had to drill out bolts, air screws themselves not just the caps, pilot jets and on 2 ocassions the air jets ...
I have also drilled out butterflies and split carbs off the racks and on more than 1 ocassion fabbed up some stuff inside a carb. My seca carb needed to get a hollow bolt, I decided a mikuni mainjet with hollowed out insides was the ticket. Yea yea, I know carbs. So send em.
Cool.
Buddha.

I got the pilot adjustment screw plug drilled out now, it took a while but it's finally out.  I also got the shimming done too (Thanks 'OHGOOD') but now I can't get the float bowl screws off.  One side w/o any problem, the other stiripped all 4 heads and tried to cut a slot for a flathead screwdriver and stripped that too.  I NEED BUDDHA's help to remove these screws.  I send you a PM Buddha, please PM me back.

Thanks,
Zhi

I just rejetted my '07 and right away started stripping screws, took a small Vice-Grip pliers and got them all out, replaced them with metric allen heads on assembly 

Can I drill the heads off and back the screw out that way or is it seized?

Quote from: zman93 on June 24, 2008, 08:14:09 AM
Can I drill the heads off and back the screw out that way or is it seized?

No need to drill, just grab the outside diameter of the screw head with the small vice-grips, big vice-grips might work too?

Quote from: zman93 on June 18, 2008, 11:08:51 AM
I have a 2001 GS 500 and I have been looking for some pictures of where the pilot adjustment screw is.  I been reading that it is behind the brass plug but I am afraid to drill it out.  There is a small pin hole in that brass plug so I didn't want to drill out something that should not be drilled out.  Does anybody have a pictures of a 2001 carb that shows exactly where the plug is?  There are 2 brass plug, 1 big with no pin hole and 1 small with a pin hole.

Here's a good picture, http://officespace.dyndns.org:8080/gstwin/2001-carb3.jpg. What you're looking for is on the far right hand side of the carb just below and adjacent to the black rubber hose.

And here's a link to the post from which this picture came, http://gstwins.com/gsboard/index.php?topic=12928.0.

Thanks for the picture.  I got the plug out now.  Now I am stuck on getting the bowl screws off.  The heads are stripped now after several attempts.  Any idea on how to get the screws off?  drill the head off and back the screw off?

Good news!  I finally got those dam screws off with a flathead screwdriver and a hammer.  I hit down on the screw first to get a good grip then tilted the screwdriver and it worked.  I started to drill small pilot hole but then decided to try one more time and it worked.