93 1500 carb rebuild

imported post

Hello to everyone. I have been watching this Forum for about a year now as I had purchased a red 92 1500 with 80K on it last July 08. Over the winter I did much to it as I am a past motorcycle tech. ( Mostly Kawasaki's) I also own a 04 Kaw. ZX10R with 40K on it. So, back to Honda, I rebuilt the front forks, Progressive springs, seals etc. Bought a used (20K) rear end, Moly 60 all the drive shaft splines and purchased used97 rear shocks ( 20K) repack all wheel bearings, did timing belts, coolant brake/clutch fluid flushes etc. I think you got the idea,,,tires, pads etc. So now that that bike is "done" I needed a new project. I just now purchased a blue 93 1500. Was a good deal and close to home. 104K on it but ran poorly and started worst. I looked for vacuum leaks and found none. I took air cleaner off and started the bike up and noticed that the right side diaphragm was not working correctly. Upon moving quickly by finger, no air sound was being made. Bad CV diaphragm. So, off to rebuilding the carbs. I also noticed that the bike is a California model and decided to get on Ebay 49 state carbs and rebuild them. I got a set of 93 carbs, 49 state, for 32.00 plus shipping. They look eat and both diaphragms were good. Not wanting to deal with the carbs again in the future, I ordered "premium" carb kits from Canada and new reproduction diaphragms ( 40.00) each and jets, needle seats, gaskets etc. 265.00 worth of parts. Was very helpful using the Cal. carbs as a reference to the USA carbs to help with re assemble of the USA carbs. I did not like the job as I was back and then away from it over a 2 week time frame. The "premium" carb kits were for many years and provided different pilots and mains and other stuff NOT for my carbs. The needle seats were taller than stock and float adjustments were adjusted. All the different o rings were a nightmare and some were NOT included in the kit. In a separate kit, from a other supplier, the accelerator pump diaphragm was nice, with a boot and spring but NO o ring to fuel feed from float bowl! Over a million 1500's sold and no one makes a good/correct complete carb kit!! So, here is the smartest thing I did. I placed rebuilt carbs on to intake manifolds and hooked up fuel line. I wanted to fill the bowls with fuel prior to installing the cards which is tricky to say the least. Upon cranking the starter, the bike acted like it wanted to start. I used my finger to pull the choke linkage to on and it fires up. I let it run on choke or else it would stall and checked operation of the accelerator pump. No fuel to top jets. Odd, as I checked to make sure the system was clean and passed carb cleaner. Turns out that the lower o ring on the tube that sends the fuel to the top of the carbs was leaking, not supplying the the pressure needed to get to accelerator jets. Easy enough, lift off carbs as nothing was attached except the fuel line and back on the bench I replaced o ring with correct/better size. Carbs BACK on manifolds, retested..all good. Saved much time with "testing" this way. I have a ultrasonic carb cleaner that I use ammonia and water in. I feel this is much safer that the "boiling water " method that I have read here. There are plastic pieces on the throttle linkage that would not stand that high temperature, I feel. I rode the bike yesterday with much of the Tupperware off, just laid seatin,test drove. No leaks, starts right up, runs 90% but I will change the plugs to get the other 10% due to possible issue with them as bike ran poorly for so long prior to me owning it. I would like to thank all of you that had your suggestions in this forum and input and idea's. This is my first writing to the forum and I hope it gave some insight to this job. I want to reach out to two people ..Randakk,,for a GREAT 1200 kit I did on a customers bike last year and his FAST response to my questions and shipping. By FAR, the BEST kit and so cheap to buy. This man knows customer service AND quality of a good product. Upon using his kit ( twice on 1200's) both bike ran like new. Too bad he does NOT offer 1500 kits..possibly some day. Next I would like to thank Jim Martino for his excellent insight to 1500 carb rebuilding. He also provided the part number of the vacuum leak he found as I changed both (2) of them. Part number needed is 17173-mn5-000 for 2 that connect to the intake manifolds on BOTH sides so 2 are needed. They are located UNDER the rubber blanket as he pointed out.Mine look OK but changed due to time and heat cycles. I will be selling the red 1992 1500 with now 93K on it..need NOTHING as I have brand new tire to install at time of sale. You can inquire about it if you like at [email protected] if you are willing to spent 6,500.00 or more..I have too many hours to count on it and money was NOT a issue upon making repair/maintenance to it as my wife rides on the back. I live just above the NY/NJ border in NY. Please do NOT write me if you are looking for a "steal" on this bike as I can keep till next spring. I have not placed any adds or ebay or anything at this time to sell it. Again, thanks for this great Forum and happy motoring!