Removing Choke Plates/Installing Primers

[dbrutherford]

Just curious how you guys got the choke plate screws out. I know that Kawasaki or Mikuni whoever "batters" the ends so they will not vibrate out ontheir own.

On an old ski I had, I simply just used a screw driver and twisted took the screws out. On this 800 SXR set of carbs I have, the screws don't want to come out at all and I am worried about stripping the heads out.

I thought of taking a dremel to the ends of the screws to remove the battering. But i don't want metal particles or grinding wheel dust falling down inside the carbs.

I have the screws turned out high enough where i can get maybe a pair of vise grips on the heads.

What do you guys suggest?

[Big Kahuna]

mine just unscrewed. Remove the carbs, grind the back off, you will be fine.

[Shonuff]

Mine unscrewed as well. Just push harder.

[SXIPro]

Dremel with a cutting wheel. Lather, rinse, repeat.

[dbrutherford]

BTW which way did you guys put in the nipples?

I was thinking of putting them in so they both point in towards each other in between the carbs. That way I can put my small T in between the two. Problem is I don't know if there will be enough room between the two to do this. Not all of my parts have arrived... :(

[D Slicker]

Same here, I think all but one came out but and that one I was able to snap off.

[tom21]

sometimes the screws snap off, sometimes they come out and sometimes they gall and just spin. grind the backside off with the dremel and the come right out . the t should fit, should! you can always grind a little off til it does. just leave enought to zip tie to. you can alway find a Y connector. :afro:

[dbrutherford]

Well I pushed harder... Two screws on one plate came completely out. The other two broke off. They were starting to strip the heads out anyways on all four screws. I also bent one shaft some. But it is all out and no metal inside my new engine. :)

[Motoman25]

i used vise grips on the two of mine that got stuck and the other two came out...

i put the nipples in towards the center and cut about an 1/8th inch off each side of the T....it fits like a glove and cleans up the engine bay of primer lines a bit.

sorry pic is a little blurry i took it fast

[dbrutherford]

Thanks motoman. That is exactly what I ma thinking of doing. I may have a bit more room since this will be on an SXR and not a Yamaha engine. My T will be brass though. I can always change it around but I like how it makes everything simple and clean. No need for an extra primer line in the way. I may or may not use a primer fitting from JSS. I bet John makes those take off fittings. Looks liek a T machined and another piece pressed into it.

[Motoman25]

yeah i got one of those take off fittings from john at jss...works well... nice ans sano and fits underneath the stock wire loom.... looks like stock minus the little bit of blue primer line hanging out

[Shonuff]

I've got mine on opposite sides and fuel lines everywhere. It's madness!

[dbrutherford]

So much for breaking the screws, one has too much thread sticking up and it won't let the shaft pull out of the carb. I will have to dremel anyways.

Anyone ever switch out the stock throttle plates and couplers for the aftermarket style ones? What about when people bore/modd the stock carbs? Probably not necessary but I remember Korn breaking his stock linkage.

Do you guys reuse the stock metal gaskets? I ordered a pair of thick green ones. But I didn't know there was a spacer and two more gaskets. What's the point of the spacer? Did the SXi Pro use it? I know it had the same carbs on it. I used to have this copper gasket sealer spray stuff from Permetex. I may go get some more of it and spray it on the metal ones. They are still in good shape. I was just worried that they might be done since they have alreay been tightened down and stressed.

I just don't want to cook down this $$$ engine. Maybe I should leave my 650 in the ski... nah I don't think so!

[Big Kahuna]

always remove carbs when removing the chokes.

Use the stock carb gaskets, if the black teflon like coating comes off, use a scotch brite pad and sand the rest off. Then get some permatex copper coat and spray the gaskets on both sides.

no benifit to change the stock linkage to AM other than looks.

[5810]

HEY, do you have to rejet-chane pop off- with primer install.

[Big Kahuna]

You shouldnt, may have to tweak the low speed a bit.

[D-Roc]

i thought you might have to adjust your pop-off??? all carbs i have worked on and setup have had then removed already. Anyone else actually remove them and set them up?
edit: actually maybe it was to remove choke and change Flame Arrestors that needs the pop-off adjusted.

[5810]

where are you guys tapping the fuel line in at.

[dbrutherford]

I haven't done mine yet since the engine isn't in my ski but I always just put the T in the fuel line some where close to the carbs yet wasn't in the way. No need for 10' of primer line stashed in the ski.


I bought some of Jet Ski SOlutions billet mixture knobs. Well John said the might not fit without come clearancing on the carbs. Yep, they hit just a little. Looks like I will have to have a little bit milled off here and there.



Another problem I have been meaning to ask you guys is how did you put the primer spigot and plug in? Mine fit in the choke shaft holes loose. I am assuming I should JB Weld or epoxy them into place. The last time I did a primer install was on a Keihin and they fit tight into those. I had to tap them into place with a hammer and a socket. These just fall into place and could just fall right out too. Any suggestions?

[SXIPro]

Most folks use JB Weld. Even the guy that supplied my primer kit to me told me to use JB if it wasn't a nice press fit.

[5810]

do you guys tap in to the main line, reserve or return line.

[dbrutherford]

I am going to do the main line after it it comes back from the fuel switch. Reserve would be ok too. But if you are leaving in the stock fuel selector, it needs to be after the switch.

[Shonuff]

I always tap the reserve and it's a bit of a pain as sometimes there's no fuel in there.

[5810]

awsome, you guys rock