Won't Start

[GS650E_81]

Well I am deep into the tear down of carb 1.

I have never done a tear down before, but I think the carb looks pretty good thus far. The float bowl gasket was barely dirty, someone may have checked the float bowls recently, the gasket looks almost brand new. The float bowl screws were easy to remove, much to my happiness as others were a straight PITA.

Bad news though..

Have a big problem though... I THINK I may have stripped the pilot jet. I removed the rubber plug, which is in good condition, loaded the slot with wd-40 and carb cleaner, and waited 2 minutes. Stuck in my crafstman screw driver and proceeded to turn, it slipped pretty bad two times. So I stopped peered in and it looks to be stripped a bit. UH OH. So I loaded it up again with wd-40 and am taking a break...

I will post pics later of the carb to the point I am now.

[GS650E_81]

Float bowl









Float bowl gasket

[tom203]

Yeah, they probably put new float bowl gasket on it to cover up the crime scene- that bowl is ugly and its gunk has likely spread. You likely will have to grind a screwdriver to fit perfectly, the blade needs to go 95% across pilot jet head, so grind the sides down to suit- it's rare to have a screwdriver just happen to fit well.

[Pendulum]

You may want to dip the carb in Berrymans for a bit to see if that'll help get that jet unstuck. Also, I've had MUCH better luck with PB Blaster compared to WD40.

[GS650E_81]

Thanks. I may pick up some pbblaster when I got get the carb dip.

[GS650E_81]

Well I just dropped the carb body.

Nice productive holiday, worked on bike ALL day, felt productive.

- Tore down carb 1, except stuck pilot jet
- degreased carb 1
- dropped in carb dip.

Another question, after pulling the float seat, I noticed a BUNCH of muck, and crud in the cavity. I also noticed that the basket looks to be tore a little. Not sure if this is a big issue or not. I made sure to clean the cavity as best I good as well as the basket. I tried to take picture but focus is not working for some reason.

Will it be okay if I have a little tear in the basket filter type piece?

[tom203]

The little filter did its job, so get another, probably $5. poke/blow that little hole in bowl bottom that feeds enrichment system tube, cuz its a good place for crud to hide.

[GS650E_81]

Pulled the carb body out of the dip. I let it soak for 22 hours.

I am still unable to remove the pilot screw...it is stripped pretty bad, guess I am screwed. Am I suppose to dip the starter plunger? If so, how do I remove what looks to be a rubber piece at the end of the needle. Also, how do I remove the basket from the needle valve and seat? or is it okay to soak that with the basket on, just remove the o-ring?

I think the carb looks pretty good, never dipped before though. It appears to have a oxidation look to it, I assume that is normal..

[koolaid_kid]

Don't dip the plunger. Use your toothbrush and carb cleaner on it instead.
Leave the basket, remove the o-ring.
The collective may have the best answer on the jet. It needs to come out no matter what. Perhaps a left-handed drill bit, turning very slowly?

[tom203]

Have you tried acetone/brake fluid soaking in jet cavity? Alternatively, assuming you have now reworked a screwdriver to fit well, you could try popping the carb body in 250 degree oven (toaster oven outside cuz it will smell), wait 1 hour as you find oven mitts , remove and attack again. The aluminum alloy body will expand more than brass jet. If all else fails, the left handed drill bit might work, if you can align it nicely, i.e. drill press.

[GS650E_81]

Have you tried acetone/brake fluid soaking in jet cavity? Alternatively, assuming you have now reworked a screwdriver to fit well, you could try popping the carb body in 250 degree oven (toaster oven outside cuz it will smell), wait 1 hour as you find oven mitts , remove and attack again. The aluminum alloy body will expand more than brass jet. If all else fails, the left handed drill bit might work, if you can align it nicely, i.e. drill press.

I don't have a toaster oven. I do however have a mapp gas hand torch lying around, from when I did some plumbing work. Would it be safe to heat one side of the carb body and see if it loosens up the jet? I am going to pick up the exact size screwdrivers mentioned in the rebuild guide today.

[tom203]

I don't have a toaster oven. I do however have a mapp gas hand torch lying around, from when I did some plumbing work. Would it be safe to heat one side of the carb body and see if it loosens up the jet? I am going to pick up the exact size screwdrivers mentioned in the rebuild guide today.

NOOOOOOOOOOOOOOOOOOOOOOOOOO!no toaster oven?? ask your neighbor to borrow one, or go to second hand store and get one for $5. The idea is not to melt carb body, but raise its temp 200 degrees for a while to stimulate stuff.

[koolaid_kid]

I would ask the GF, if present, to go shopping for a while and use the kitchen oven. I have done so before while curing the black paint on carbs. It smells a bit, but nothing overpowering.
I picked up an old toaster oven for a song and that is what I use now. Much easier to relocate also.

[Suzuki mad]

Did you read the pages on carb cleaning on bascliff's welcome page?

Did the 650G tank fit?

[GS650E_81]

Did you read the pages on carb cleaning on bascliff's welcome page?

Did the 650G tank fit?

Yes, I read it about 10 times, yet STILL used the wrong size screwdriver..

Yes the tank seems to fit.