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FZ (1984-1992)
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Yamaha FZ (1984-1992) [110/200] Carburetor overhaul general information

Yamaha YX600 (1984-1992) [110/200] Carburetor overhaul general information

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3 4 Chapter 3 Fuel and exhaust systems complete carburetor overhaul and even then the screws should be returned to the r original settings The pilot screws on other models are accessible but the use of an exhaust gas analyzer is the only accurate way to adjust the idle fuel air mixture and be sure the machine doesn t exceed the emissions regulations 2 If the engine runs extremely rough at idle or continually stalls and if a carburetor overhaul does not cure the problem take the motorcycle to a Yamaha dealer service department or other repair shop equipped with an exhaust gas analyzer They will be able to properly adjust the idle fuel air mixture to achieve a smooth idle and restore low speed performance 5 Carburetor overhaul general information 1 Poor engine performance hesitation hard starting stalling flooding and backfiring are all signs that major carburetor maintenance may be required 2 Keep in mind that many so called carburetor problems are really not carburetor problems at all but mechanical problems within the engine or ignition system malfunctions Try to establish for certain that the carburetors are in need of maintenance before beginning a major overhaul 3 Check the fuel filter the fuel lines the tank cap vent except California models the intake manifold hose clamps the vacuum hoses the air filter element the cylinder compression the spark plugs and the carburetor synchronization before assuming that a carburetor overhaul is required 4 Most carburetor problems are caused by dirt particles varnish and other deposits which build up in and block the fuel and air passages Also in time gaskets and O rings shrink or deteriorate and cause fuel and air leaks which lead to poor performance 5 When the carburetor is overhauled it is generally disassembled completely and the parts are cleaned thoroughly with a carburelor cleaning solvent and dried with filtered unlubricated compressed air The fuel and air passages are also blown through with compressed air to force out any dirt that may have been loosened but not removed by the solvent Once the cleaning process is complete the carburetor is reassembled using new gaskets O rings and generally a new inlet needle valve and seat 6 Before disassembling the carburetors make sure you have a carburetor rebuild kit which will include all necessary O rings and other parts some carburetor cleaner a supply of rags some means of blowing out the carburetor passages and a clean place to work It is recommended that only one carburetor be overhauled at a time to avoid mixing up parts 6 Carburetors removal and installation Warning Gasoline Ipetrol is extremely flammable so take extra precautions when you work on any part of the fuel system don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage where a natural gas type appliance such as a water heater or clothes dryer is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a fire extinguisher suitable for a class B type fire flammable liquids on hand Removal Refer to illustrations 6 4 and 6 23 1 Remove the fuel tank see Section 2 2 Disconnect the negative cable from the battery XJ FJ600 models 3 Disconnect the throttle cable and choke cable if equipped see Sections 10 and 11 4 Loosen the clamping bands on the air cleaner joints and intake joints the rubber tubes that secure the carburetors to the air cleaner air box and engine see illustration 5 Remove the air cleaner case bolts and slide the air cleaner case 6 4 Loosen the clamping bands around the air box joints arrow and the intake manifold tubes backward to disengage the air cleaner joints from the carburetors 6 Slide the carburetors backward to disengage them from intake joints then remove the carburetor assembly FZ600 models 7 Remove the starter relay the regulator reclifier and the batt see Chapter 8 8 Loosen the clamping bands on the air cleaner joints and inta joints the rubber tubes that secure the carburetors to the air clea air box and engine see illustration 6 4 9 Remove the air cleaner case bolts and slide the air cleaner ca backward to disengage the air cleaner joints from the carburetors 10 Disconnect the throttle cable from the throttle pulley see Se tion 10 11 Disconnect the air vent hose from the ca buretor assembly 12 Remove the fairing stay 13 Slide the carburetors backward to disengage them from intake joints then remove the carburetor assembly YX600 Radian models 14 II you re working on a YX600 Radian remove the carbure covers and side covers see Chapter 7 15 Remove the fuse block mounting screws see Chapter 7 a remove the igniter unit see Chapter 4 16 Remove the battery case bolts and air cleaner air box bolts 17 Loosen the clamping bands on the air cleaner joints and inta joints the rubber tubes that secure the carburetors to the air clea air box and engine seo illustration 6 4 18 Slide the air cleaner air box and the battery case backward disengage the air cleaner joints from the carburetors 19 Disconnect the choke cable and throttle cable from the carbure assembly see Sections 10 and 11 Disconnect the air vent hose 20 Loosen the clamp screws on the intake manifolds the rub tubes that connect the carburetors to the engine see illustration 6 4 21 Slide the carburetors backward to disengage them from intake joints then remove them All models 22 After the carburetors have been removed stuff clean rags into intake manifold tubes to prevent the entry of dirt or other objects 23 Inspect the rubber intake joints see illustration If the cracked or brittle replace them Installation 24 Installation is the reverse of the removal Steps with the follow additions a Adjust the throttle grip freeplay see Chapter 1 b Check and if necessary adjust the idle speed and carbure synchronization see Chapter 1