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First things first: Thanks to the many of you who have helped me with this. Solarman for carb rebuild suggestions, Artdf175 for general hand-holding, Pniksnut and Hoosmatroos for tool suggestions, and others I'm unfortunately probably forgetting.
Background: 2003 DF 25 4-stroke triple. It ran crappy after sitting for a few years, even after running several hours of Seafoamed ethanol free gas through it. The advice I got here was to man up & rebuild the carbs. A scary thought .. A little more complex than the Harley carbs I've done in years past.
I did it, though. Per Solarman's advice, I took pix & did only one carb at a time. For cleaning, I used an ultrasonic cleaner from HF with a Berryman carb-cleaning solution then blew everything out with compressed air. Didn't have to change any screw settings as my carbs all have sealed pilot screws. Manual says don't mess with them. (Also didn't change any idle screw settings on middle & top carbs, so synchronizing shouldn't be affected.) Then, new gaskets & O-rings + new fuel lines from filter & pump to carbs. New fuel filter, plugs & thermostat. New primer squeeze bulb. Probably should replace the fuel hose on each side of the bulb but haven't done that yet. I did NOT, at this point, rebuild the fuel pump. Impeller has also been replaced.
Results: Started on first try & ran like a scalded dog!! I had the idle set way too fast (trying to get it to run with dirty carbs) but now have it idling around 900. Smooth & quiet. Really purrs. Now I know what it's supposed to sound like! I noticed, though, that it occasionally coughs, maybe every 30-60 seconds or so. Note: my terminology might not be quite right; what I call a "cough" might be a "sneeze" to someone else. Anyway, thinking this might be a lean condition, I'm going to run it a bit longer in the barrel & then check the plugs for a lean condition.
So, any thoughts on this coughing thing? Aside from that, I think I'm really getting close! Can you tell I'm excited??
Thanks again, all!
Background: 2003 DF 25 4-stroke triple. It ran crappy after sitting for a few years, even after running several hours of Seafoamed ethanol free gas through it. The advice I got here was to man up & rebuild the carbs. A scary thought .. A little more complex than the Harley carbs I've done in years past.
I did it, though. Per Solarman's advice, I took pix & did only one carb at a time. For cleaning, I used an ultrasonic cleaner from HF with a Berryman carb-cleaning solution then blew everything out with compressed air. Didn't have to change any screw settings as my carbs all have sealed pilot screws. Manual says don't mess with them. (Also didn't change any idle screw settings on middle & top carbs, so synchronizing shouldn't be affected.) Then, new gaskets & O-rings + new fuel lines from filter & pump to carbs. New fuel filter, plugs & thermostat. New primer squeeze bulb. Probably should replace the fuel hose on each side of the bulb but haven't done that yet. I did NOT, at this point, rebuild the fuel pump. Impeller has also been replaced.
Results: Started on first try & ran like a scalded dog!! I had the idle set way too fast (trying to get it to run with dirty carbs) but now have it idling around 900. Smooth & quiet. Really purrs. Now I know what it's supposed to sound like! I noticed, though, that it occasionally coughs, maybe every 30-60 seconds or so. Note: my terminology might not be quite right; what I call a "cough" might be a "sneeze" to someone else. Anyway, thinking this might be a lean condition, I'm going to run it a bit longer in the barrel & then check the plugs for a lean condition.
So, any thoughts on this coughing thing? Aside from that, I think I'm really getting close! Can you tell I'm excited??
Thanks again, all!
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