Bit the bullet ... 550 carb rebuild underway..

[jaywelchy]

So I got my O rings, got my main jets, tutorial, Berrymans, etc, etc.

Still chasing the over 5000 rpm power ...

I have to say ... the carbs looked nice inside .. someone has been inside.

The pilot screws are exposed, so someone drilled out the caps already. But the o rings around them were toast.

I only had 2 major issues ..
1. had to cut a slot in one of the large bolts to un-gang the carbs ... no biggie.
2. the pilot screw on #3 carb had a totally wallared out head. It looked like a bowtie, not a screwdriver slot. I managed to grind and shape a few screwdrivers to try fit the elongated slot, but to no avail. It would move a turn either way ... but wouldnt come out. Just not enough material left. I figured after about an hour, the threads were toast in the aluminum carb, and I started drilling with a 1/16" bit .. after going up a couple sizes, I found a torx head bit that fit the new hole in the center, and walla! out it came ... the biggest suprise was I didnt at all damage the threads! So I need one pilot screw .........

There are no pilot jet plugs ... do I need them??

The float needle and seat look new .. but the o rings around the seat are junk.

Also, pilot screw adjustments were all over the place ... 2.5 turns on 1, 4.5 on 2, not sure on 3, and 4.25 on 4.

Honestly ... not finding anything alarming, or indicating an issue with my 5000 rpm "wall".

Guess I will see ....

Taking a ton of pics for reference, though its all pretty straight forward. I can say the intake boots on the engine have new hex head bolts ... yet I got the O rings for that too ....
Jason

[hikermikem]

There are no pilot jet plugs ... do I need them??

Jason

YES... might want to consider raising the needles a bit too when you re-assemble.

[Nessism]

The missing pilot plugs will cause running problems, maybe even that wall you speak of.

[jaywelchy]

Thx guys .. will get those plugs.

Cant find a pilot screw ...

[jaywelchy]

Thx DP ...

got the carbs back togethor .. most everything looked ok, though 2 O rings were chewed up.

Went through all methodically, and found 2 issues .. No pilot jet plugs, made some up so got that corrected. And the pilot screw adjustments were all over the board. #3 pilot screw was all but seized, and the screw head was wallared out and un-usable. So thinking someone tried to compensate by adjusting the other 3. I got the screw out, corrected the slot for a screwdriver, and in it goes. So we will see how this all turns out when its back in the bike.

Going to use the float check/adjust technique in the tutorial .. just need to find a correct size screw for the bottom of the float bowl.

I did quick test run(float level check) with a plastic fitting and hose, which leaked a bit ... but the test showed the float to be to low on # 1 carb.

I dunno ... not real confident the carbs are my issue ...

[jaywelchy]

S U C C E S S !!


got it back togethor today .. bench set the floats in spec, and set all pilot screws to 3 turns out ..

After a quick minute to warm up, idle was set to 1200 (I like it a bit high), and off I went.

I was suprised that it ran so seamlessly, and it is a very happy little bike in the above 6000 rpm range. Awesome .. happy with the work put in, happy with the results ..

the way it is running, starting, idleing, etc... I dont need any more adjustments. Sweet!

Jason

[jaywelchy]

The missing pilot plugs will cause running problems, maybe even that wall you speak of.

This may have been the issue. I made some up in the shop, and although I am not sure what the purpose is of these little plugs, it may have been my main issue all along.

These carbs have been gone through (not properly mind you) 4 times in 300 miles, or just a couple months .. with no results till now.

Jason

[Nessism]

Just like everyone told you in your other thread, paying someone to work on your bike is a waste of money and only creates frustration. Hope you learned your lesson.

Oh, and glad you figured it out!