the Carburetor Chronicles - Page 2 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #26 of 51 (permalink) Old 11-1-2019, 7:19 PM Thread Starter
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productive day, finished the refurb on these 500's for a W coast member who had leaking rail seals. Orings rock hard and flattened, no surprise upon inspection. Full service, all new consumables, circuits cleared, setup and tested. Came out pristine in and out, as photos indicate. He'll be good for a long while.
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Last edited by ducatiman; 11-1-2019 at 7:21 PM.
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post #27 of 51 (permalink) Old 11-2-2019, 10:46 AM Thread Starter
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With further effort, when applicable, I'll be detailing slides to a greater degree. These in refurb #71 came out very near to "as shipped" factory condition. No buildup, telltales, scratches = no friction, nothing to impede movement.
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Last edited by ducatiman; 11-2-2019 at 10:53 AM.
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post #28 of 51 (permalink) Old 11-4-2019, 10:59 PM Thread Starter
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a bit out of the norm.....a Carter carb off of a 1949 IHC pickup truck in the house. Immediately encountered a "hesitant" throttle plate, for beginners showered the linkages with some PB Blaster, got some movement but will let sit overnight.
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“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #29 of 51 (permalink) Old 11-5-2019, 9:50 PM Thread Starter
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Carter disassembled, pretty straightforward. As this thing is really old, its certainly different yes, but not terribly complicated. Component cleaning process now underway. Accel pump leather plunger "cup" rock hard, main fuel bowl chamber floor rust and a ball bearing check valve inoperative, buried under the rust, on and on.

Appropriate carb kit sourced.
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File Type: jpg carter2 (2).jpg (130.8 KB, 16 views)
File Type: jpg carter3.jpg (116.8 KB, 14 views)
File Type: jpg carter4.jpg (96.1 KB, 13 views)
File Type: jpg carter5.jpg (79.5 KB, 10 views)
File Type: jpg carter6.jpg (141.9 KB, 7 views)

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; 11-6-2019 at 9:11 AM.
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post #30 of 51 (permalink) Old 11-9-2019, 1:08 PM Thread Starter
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In the meantime, another refurb done for a member's set of fi' hunners.

A curious finding with a previously installed aftermarket (All Balls?) pilot screw just not fitting quite right, threading in but not fully seating. The screw tip *should* normally protrude from the venturi just a mm or 2....at least using an OEM pilot screw. This one clearly did not. Very close inspection in comparison to a factory screw revealed a different thread design at each head. I will not trust nor rely on these aftermarket screws within my service efforts. As a result, I opted to install factory OEM screws from my salvage spares.

And implemented my new efforts on the slide surfaces, to success. Perfect, impressive slide action, like new again.
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Last edited by ducatiman; 11-9-2019 at 1:19 PM.
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post #31 of 51 (permalink) Old 11-9-2019, 2:33 PM
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Quote:
Originally Posted by ducatiman View Post
Very close inspection in comparison to a factory screw revealed a different thread design at each head. I will not trust nor rely on these aftermarket screws within my service efforts. As a result, I opted to install factory OEM screws from my salvage spares.
Can't argue with that.

2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #32 of 51 (permalink) Old 11-9-2019, 3:10 PM Thread Starter
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Yessir, the market now being flooded with non-original, copy cat carb kits....I've now run into hardware issues, wrong needle and pilot screw issues, 3 times on 3 separate occasions, on 2 EX's and 1 ZX750 carbsets in the last year or so.

Whether its basic packaging errors (poor quality control, wrong parts in kits) or actual design flaws....I'd dissuade against blindly jamming these copycat parts into place without very careful scrutiny, comparing to original whenever possible. If any doubt, default to using original equipment parts.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; 11-10-2019 at 10:52 AM.
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post #33 of 51 (permalink) Old 11-15-2019, 11:07 PM Thread Starter
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Carter beginning to take shape, though still disassembled. Micro-pinhole discovered in the original brass float, I immediately ordered the superceded, modern plastic version.

Super glad *I* found the pinhole.....prior to completion, return shipping and owner install. Troubleshooting...why I'm contracted to do what I do.

In the end...will be a 100% functional and restored carb! Stay tuned.....
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Last edited by ducatiman; 11-15-2019 at 11:38 PM.
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post #34 of 51 (permalink) Old 11-16-2019, 12:54 PM
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Hard to believe that over 3 liters of straight six engine could manage to breath through such a tiny venturi. Takes me back to the '56 IHC Travel-all that I owned back in the seventies. Mine was an ex-logging company 4X4 crummy, had a 4-speed with hi-lo transfer case and super low axle ratios (top speed about 55). It got the worst gas mileage of any vehicle I have ever owned, about 8 miles per gallon. After discovering just how bad the mileage was, I quit using it for transportation and only used it when I needed to haul lumber, pull stumps, or plow snow. Looks like a fun project..
post #35 of 51 (permalink) Old 11-16-2019, 2:09 PM Thread Starter
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1949 International pickup owner in the Carolinas somewhere, the Carter carb goes on this thing. Sitting for some time, designed in a long, bygone era....I'd be surprised if it topped out at more than 55.
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File Type: jpg carter12.jpg (130.0 KB, 11 views)

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Last edited by ducatiman; 11-17-2019 at 10:50 AM.
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post #36 of 51 (permalink) Old 11-16-2019, 2:22 PM Thread Starter
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Turning my attention to yet another set of 5 hunnerts in the house today. Nothing unusual...except pilot jets really frozen in place...a wrestling match to dislodge them revealed....100% clogged. Not unexpected...otherwise, routine stuff, the usual evidence of corrosion, sitting some time. With a surprise or 2.

Before pics.....
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File Type: jpg wise2.jpg (82.6 KB, 4 views)
File Type: jpg wise3.jpg (88.2 KB, 4 views)
File Type: jpg wise4.jpg (143.6 KB, 4 views)

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; 11-16-2019 at 8:56 PM.
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post #37 of 51 (permalink) Old 11-16-2019, 6:19 PM Thread Starter
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some after pics

Comments.....
Anti tamper caps still present, had to drill them out to get to the pilot screws to remove/fully clean the circuit. In doing so, discovered the factory screw settings to be near *closed* on both carbs! Sure enough, the needle tips were projecting way into the venturi! How did this thing ever run? What were the factory boys thinking?
In addition, super tight pilot jets both 100% clogged upon removal/inspection.
Float valves were "dead"...springs fatigued, low float level= high fuel level. All corrected with new float valves and adjustment, confirmed during wet testing.
Otherwise standard procedure, all brass shining like new, all openings back to their intended factory specs. All new orings, stainless hardware, the rail filter installed.

Look at the slides shining! (with perfect action) I predict these'll be some fine runners now.
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File Type: jpg wise5.jpg (117.8 KB, 8 views)
File Type: jpg wise6.jpg (117.4 KB, 7 views)
File Type: jpg wise7.jpg (136.5 KB, 8 views)
File Type: jpg wise8.jpg (115.0 KB, 7 views)
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Last edited by ducatiman; 11-16-2019 at 6:33 PM.
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post #38 of 51 (permalink) Old 11-17-2019, 10:11 AM
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Hard to believe that over 3 liters of straight six engine could manage to breath through such a tiny venturi. Takes me back to the '56 IHC Travel-all that I owned back in the seventies. Mine was an ex-logging company 4X4 crummy, had a 4-speed with hi-lo transfer case and super low axle ratios (top speed about 55). It got the worst gas mileage of any vehicle I have ever owned, about 8 miles per gallon. After discovering just how bad the mileage was, I quit using it for transportation and only used it when I needed to haul lumber, pull stumps, or plow snow. Looks like a fun project..
I think the '40s flathead engine was actually a little over 200 cubes. The later overhead valve engines were bigger. They were all undersquare, low rpm stump pullers.

My father's '59 pickup would top 70. I know because that's how fast it was going when it started to shimmy so badly my father couldn't keep it on the highway (and he was a professional truck driver). Heck, we could hardly SEE the highway. We ended up sailing along the median strip. Thankfully, when it hit the median strip it stopped shimmying, otherwise we would have been dead. I never looked at that truck the same way afterwards.

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post #39 of 51 (permalink) Old 11-17-2019, 2:06 PM
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Yeah, I noticed the '49 in the pic was a flathead so sometime between '49 and '56 they switched because mine was a Black Diamond 240 cube OHV. The oil bath air cleaner, the huge horn, and the bracing rods are familiar, though, also the ID plate on the firewall. I still have the ID plate from mine kicking around in a desk drawer somewhere. The rest of it is long gone.

The weird thing is that I haven't even thought of that old monster (we called it the Stegosaurus because it was dark green with a high humped back) for decades, then ducatiman posts his pics and the very next day I spot a nicely restored mid-50's IHC pickup in the local grocery store parking lot. Go figure. I hung around for a bit hoping I could catch the owner and get a closer look, but no luck. Then later the same day I spotted it parked in the back forty of a ranch about 15 miles out of town. Now that I know where it lives I'll catch up to the guy sooner or later and take a little trip down memory lane.
post #40 of 51 (permalink) Old 11-17-2019, 10:40 PM Thread Starter
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I'm no expert by any means, but FWIW the model of the IH truck is KB2 and the Carter carb is model BBR-1.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #41 of 51 (permalink) Old 11-24-2019, 6:19 PM Thread Starter
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Carter now done, going home Monday A couple bee 4 and afters

details:
*new gaskets
*newer design, updated plastic float replacing holed original brass unit
*new needle/seat
*new accelerator pump
*all drillings/circuits/ball check valves cleared and functional
*all linkages now free and operational
* medium strength (blue) loctite used on segment screws
*noted and retained all original settings (as vehicle ran prior, though long ago)

thats all, folks
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File Type: jpg carter1.jpg (134.8 KB, 8 views)
File Type: jpg carter14.jpg (103.2 KB, 9 views)
File Type: jpg carter3.jpg (116.8 KB, 9 views)
File Type: jpg carter10.jpg (104.1 KB, 9 views)

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Last edited by ducatiman; 11-24-2019 at 6:38 PM.
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post #42 of 51 (permalink) Old 11-24-2019, 10:18 PM
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Well, there's your foot in the door of the vintage auto world. Next thing you know you'll be redoing these.
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post #43 of 51 (permalink) Old 11-25-2019, 9:28 AM Thread Starter
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Fat chance, those beautiful works of art start at $4K and run through mid $5K, specially built and marketed, limited to the extremely rich collector. Few and far between. Packard carb models for antique Cadillac into $8K! Wow, thats JUST the carb set!

Those in another galaxy....I'm quite satisfied renewing our affordable, common little Mikuni and Keihin!

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #44 of 51 (permalink) Old 11-25-2019, 9:15 PM
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You're probably better off that way.
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post #45 of 51 (permalink) Old 11-25-2019, 10:37 PM
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Yeah, and I'm betting yours work better....
post #46 of 51 (permalink) Old Yesterday, 6:28 PM
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Basement find thought of u . You interested?
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post #47 of 51 (permalink) Old Yesterday, 6:37 PM Thread Starter
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for what bike? look like 70's vintage early Mik CV?

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #48 of 51 (permalink) Old Yesterday, 8:47 PM
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for what bike? look like 70's vintage early Mik CV?
Honestly have no idea putting a new electrical service on a house and this was layin on a shelf . It was covered with about 20 years of dust lol . Blew it off enough for the pics . Free to u I'll eat the shipping to put it in good hands . Mabe it will help somebody and I can use the karma lol
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post #49 of 51 (permalink) Old Yesterday, 8:49 PM
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Forgot to say homeowner gave it to me . He thought it was cool and didnt know it was there . I told him about u helping me out and he said he'd like to see if maybe someone could get some use out of it .
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post #50 of 51 (permalink) Old Yesterday, 9:01 PM Thread Starter
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I'll PM in a few

looking again, these are ancient vintage, pre CV. Look familiar to anyone?

Edit- I believe they are from snowmobile application....unknown vintage, brand and model.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; Yesterday at 10:20 PM.
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