Carb Rebuild ( ST1100 ) *

[KoTAOW]

Original article can be viewed here:
http://koczarski.com/ST1100/CarbRebuild/Carbs.htm

Submitted by Adam Koczarski.

~~~

Carb Rebuild

Check out the water damage to the drain screws and the deposits it caused in the
bottom of the bowls. This is after cleaning them. About $70 apiece to replace
the carb bowls! Ouch!! I was able to find a complete set of carbs on Ebay for $70!



Sliders removed.


All the internal parts layout out and grouped by carb number.


The new pilot and main jets.


Close up of the slider chambers.


All the floats, jets and holders removed.


Reinstalling the jets and holders. Keep everything numbered so you don't mix up
the parts. The paper shown shows the number of turns on the idle screws for each
carb.


The carbs bowls arrive. They look clean, but had a little damage from the wreck.


The bowl on the left had an impact mark and the right one was missing the drain
nipple.


Close up of the dent.


The resulting crack on the inside. It doesn't go all the way through.
The bowl holds liquid.


The drain screws are in way better shape than mine were.


To repair the broken nipple I cut a good one from one of my carbs. Then I drilled
the holes out a bit and used a 3/32 aluminum pipe to splice the pieces together.
JB weld was used to attach the parts.


The pieces in place.


The finished product. I used Quicksteel on the inside and outside of the carb bowl
on the right. It's suppose to be OK for patching fuel tanks, but I'm thinking I'll
just use my original bowl. It was the cleanest of the four, plus I have a new drain
screw for it. I just don't trust having it in my carbs.


Just about done with the reassembly. When I went to reinstall the drain hoses
they didn't reach the nipples. I realized I had switched the bowls for carb #1
and #2! They fit, but the hoses didn't. The drain screws would also be in a spot
not easily accessed! As everyone says, pay close attention to which part came
from where.


Checking the float height. Should be 7mm. Mine were all at 9mm??


Putting back the last slider.


The carbs are all in at this point. Look at all that room in there with the PAIR
system removed!! The bike idles WAY better now and responds to the throttle
quicker from low RPMs. This was probably due to the two idle jets that looked
plugged. I should have done this a long time ago! Like any other major job I've
attempted this one wasn't as bad as it seemed it would be. You just need the time
to do it right.


Some great info on how carbs work here. I haven't done, or condone, the airbox
modifications show there though.

[KoTAOW]

Here is a fiche drawing showing Carb Components:

( EXAMPLE ONLY )

Item Number	Part Number	Description	Quantity	Approx. Price Each
1	16010-MAJ-D00	GASKET SET (Honda Code 8535981)	4	$  24.85
	16010-MT3-610	GASKET SET (Honda Code 3489010)	4	$  24.85
2	16011-MR5-672	VALVE SET, FLOAT (Honda Code 3202504)	4	$  43.65
3	16013-MAH-000	FLOAT SET (Honda Code 4523742)	4	$  28.61
	16013-ML7-004	FLOAT SET (Honda Code 2402774)	4	$  28.61
4	16015-MT3-610	CHAMBER SET, FLOAT (Honda Code 3489028)	2	$  97.21
5	16016-MAJ-D00	SCREW SET (Honda Code 8600413)	4	$  12.08
	16016-MT3-670	SCREW SET A (Honda Code 3489036)	4	$  12.08
6	16018-MT3-610	LINK B SET, STARTER (Honda Code 3489051)	1	$  47.39
7	16023-MT3-610	CHAMBER SET, FLOAT (Honda Code 3489077)	2	$  97.21
8	16028-MT3-610	SCREW SET B (Honda Code 3489101)	1	$  31.43
9	16031-MR7-004	LINK B SET, STARTER (Honda Code 3445061)	1	$  47.39
10	16037-MT3-610	PLATE SET (Honda Code 3489127)	4	$  14.45
11	16046-MG9-681	VALVE SET, STARTER (Honda Code 1918507)	2	$  37.84
12	16046-MG9-681	VALVE SET, STARTER (Honda Code 1918507)	2	$  37.84
13	16048-MM5-671	VALVE SET, AIR CUT (Honda Code 2614477)	4	$  84.37
14	16050-KV0-671	SPRING, VACUUM PISTON (Honda Code 2892974)	4	$  10.97
	16050-KV0-721	SPRING, VACUUM PISTON (Honda Code 3041100)	4	$  10.97
15	16075-KAF-000	COLLAR SET (Honda Code 3119120)	4	$    8.02
16	16107-MT3-610	TOP (Honda Code 3489259)	4	$  31.43
17	16111-MT3-610	PISTON, VACUUM (Honda Code 3489267)	4	$104.48
18	16151-MT3-670	NEEDLE, JET (Honda Code 3489358)	2	$  15.59
19	16151-MT3-730	NEEDLE, JET (Honda Code 3681319)	2	$  19.11
20	16165-MT3-610	HOLDER, NEEDLE JET (Honda Code 3489366)	4	$  22.13
21	16178-MT3-610	WASHER, PLAIN (Honda Code 3489374)	4	$   1.39
22	93500-04010-0A	SCREW, PAN (4X10) (Honda Code 0188359)	14	$     .99
	93500-04010-1A	SCREW, PAN (4X10) (Honda Code 0681221)	14	$     .99
23	93500-05012	SCREW, PAN (5X12) (Honda Code 0057133)	1	$     .99
	93500-05012-0A	SCREW, PAN (5X12) (Honda Code 0173567)	1	$     .99
	93500-05012-00	SCREW, PAN (5X12) (Honda Code 1091859)	1	$     .99
	93500-05012-1A	SCREW, PAN (5X12) (Honda Code 0422451)	1	$     .99
24	93892-04008-00	SCREW-WASHER (4X8) (Honda Code 0691790)	8	$     .99
	93892-04008-10	SCREW-WASHER (4X8) (Honda Code 1171826)	8	$     .99
26	93892-04016-00	SCREW-WASHER (4X16) (Honda Code 0692053)	16	$     .99
	93892-04016-10	SCREW-WASHER (4X16) (Honda Code 1376011)	16	$     .99
27	99101-GHB-1250	JET, MAIN (#125) (Honda Code 4527222)	4	$   3.57
	99101-393-1250	JET, MAIN (#125) (Honda Code 0711564)	4	$   3.57
28	99103-MT3-0380	JET, SLOW (#38) (Honda Code 3699394)	4	$  14.32

[KoTAOW]

Comments by George Catt:

Just did the carb clean routine on two bikes over the weekend:
1. Jay's Project Bike, 91 SSMST with 48K miles, had sat for several years. Idle jets were blocked but cleaned up easily, float bowls weren't bad. Cleaned, reassembled, started up easily, did the air-flow meter to adjust then did the 50 RPM drop adjust on the air screws. Running great now, wouldn't idle at all before.
2. David's really clean 96. Only 3300 miles on this one. Sat for ~5 years. Same routine, low speed jets were _really_ plugged. Got'em cleaned and reinstalled. Started right up. Required _no_ adjustments.

Gratifying to rescue two derelicts, both bikes now have good home.