the Carburetor Chronicles - Page 2 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #26 of 32 (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 32 (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 32 (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 32 (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 carter4.jpg (96.1 KB, 7 views)
File Type: jpg carter5.jpg (79.5 KB, 7 views)
File Type: jpg carter6.jpg (141.9 KB, 5 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 32 (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 32 (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 32 (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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