Suzuki GS1000 carburettor horror

[NitroGS]

Hi Guys,

I feel pig sick. Took the carburettors off much loved 1979 Suzuki GS1000 (VM's) tonight to give them a full overhaul because she had been running a bit lame. I thought to myself when I looked down the manifolds from the cylinder end what is that very small protrusion just in front of the slides. It suddenly dawned on me that it was the pilot fuel screws on cylinders 1 and 2. I proceeded to remove the mains, pilot jets, floats and needle and lastly the pilot fuel screws. On removing the carbs 3 and 4 screws they showed signs of wear but nothing prepared me from the shock of removing the screws from carbs 1 and 2. Horror! the end tips were missing, looking down the threads I can see the ends. Is this the end of my carbs guys[-o<


Just an asisde are there any GSR members from Tennesee please, I have a massive favour to ask, if there is can you please PM me please.

[Nessism]

Horror! the end tips were missing, looking down the threads I can see the ends. Is this the end of my carbs guys[-o<

This is a common problem; tips of pilot fuel screw breaks off and sticks in the carb body. You need to take a sharp punch of some sort and drive the broken tip backward from inside the carb body to remove. Pretty easy to get the broken tips out. My understanding is that all the VM pilot fuel screws are the same, regardless of the size. I used parts from a 750 in my 550 since Z1 sells a kit that includes the screw.

http://www.thegsresources.com/_forum/showthread.php?t=82559&highlight=pilot+fuel+screw

Good luck.

[NitroGS]

Hi Nessism,

You know whenever things look as black as can be, there is always a knight in shining armour around the corner. Brilliant advice I am going to give it ago this afternoon, indebted to your knowledge.

[NitroGS]

Fuel Pilot Screws the curse of!!!

Hi Guys

Spent 3 hours today on the old carbs trying to remove the sheared fuel pilot screws on 1 and 2 carbs. Rigged a strong needle tightly secured to a long allen key, in order to be able to pushout the tips from access down the throttle slider bore. Located my needle on the first sheared screw pressed and out it popped (big smiles). Now for the awkward one (4mm of screw sheared) located needle/allen key arrangement pushed and pushed but she would not move. Sprayed WD40 both sides of the sheared screw, she still won't move. I suppose it has defeated me and it is looking like another bank of carbs. Unless you guys know different

[rickt]

There may yet be hope

I had much the same problem with two of four carbs on my '78 GS750. No amount of pushing with sharp objects would dislodge the remains of the broken needles. Out of desperation I contacted a shop that specializes in vintage motorcycle carb repairs. They had a drilling instrument that was able to drill out the remains of broken needles. It is a very delicate process as the drill alignment is critical and the hole in the carb body is very small. I have the carbs together, but the bike is still mostly in pieces so I haven't tested them.

You may be able to find a similar ship and salvage the carbs.

rickt

Hi Guys

Spent 3 hours today on the old carbs trying to remove the sheared fuel pilot screws on 1 and 2 carbs. Rigged a strong needle tightly secured to a long allen key, in order to be able to pushout the tips from access down the throttle slider bore. Located my needle on the first sheared screw pressed and out it popped (big smiles). Now for the awkward one (4mm of screw sheared) located needle/allen key arrangement pushed and pushed but she would not move. Sprayed WD40 both sides of the sheared screw, she still won't move. I suppose it has defeated me and it is looking like another bank of carbs. Unless you guys know different

[IanFrancisco]

Hi Guys

Spent 3 hours today on the old carbs trying to remove the sheared fuel pilot screws on 1 and 2 carbs. Rigged a strong needle tightly secured to a long allen key, in order to be able to pushout the tips from access down the throttle slider bore. Located my needle on the first sheared screw pressed and out it popped (big smiles). Now for the awkward one (4mm of screw sheared) located needle/allen key arrangement pushed and pushed but she would not move. Sprayed WD40 both sides of the sheared screw, she still won't move. I suppose it has defeated me and it is looking like another bank of carbs. Unless you guys know different

I think gentle impact could be your friend in this instance. I would get a real punch/drift pin instead of your needle-on-an-allen wrench and a few gentle taps could be all you need. Beats buying a bank of carbs.

[t3rmin]

Yeah if you're going to buy new carbs anyway, why not try a little harder? Worst you could do is make it worse and you'll have to buy...

[NitroGS]

Hi Guys

Another day has dawned just arose it is 08:00hrs in the UK. Renewed enthusiasm and vigor. Your absolutely right I have nothing to lose. Going to give it another shot after my bowl crispies. Will keep in touch




Just an asisde are there any GSR members from Tennesee please, I have a massive favour to ask, if there is can you please PM me please.