anybody have a good source for carb kits?

I'm looking for carb rebuild kits for my '81 xj550
I found them at old bike barn for $19.95 a pop. Once you add shipping though I'm looking at like $90-100 bucks for the whole job. Does anybody know where to find them cheaper? Or better yet, is it even necessary to rebuild if i do a good cleaning instead?

 

Kits vary a good deal in content. Chacal on this site has every part you could need at reasonable prices and shipping rates and he turns orders fast. Just PM him with your needs.

You can do a good clean without a kit as long as all your seals and o rings are in good shape. I did mine twice then just rebuilt replacing everything. Huge difference when I did but everyone had different needs.

 

Here they are, along with a few other items you might need:


MIKUNI CARB REBUILD PARTS:


NOTE: Mikuni carbs were originally used on all Yamaha XJ550 models (BS28 series carbs), all XJ650 Turbo models (BS30 series carbs), all XJ700-X and XJ750-X models (BS33 series carbs), XJ900RK model (BS35 series carbs), and XJ1100 models (BS34 series carbs). All other XJ models from this era (XJ650 non-Turbo models, XJ700 non-"X" models, and all XJ750 non-X models) used Hitachi carbs.

NOTE: "OEM" refers to an original Yamaha factory part, whereas "Replacement" or "Aftermarket" refers to a part not made by Yamaha or one of their original suppliers. NOTE THAT AN "OEM" PART may be made by Yamaha's original supplier, even though such part is no longer serviced through the Yamaha factory parts system.


j1) XJ models Mikuni BS28/30/33/34/35 USED PARTS.....jets, bowls, bodies, diaphrams/slides, floats, brackets, screws, etc. I have multiple used sets of carbs that I can part out for the items that you need, let me know what specific parts you're looking for.



MIKUNI THROTTLE SHAFT REBUILD PARTS:



MIKUNI THROTTLE SHAFT SEALS:


aaa) OEM and aftermarket Mikuni carb THROTTLE SHAFT V-SEALS (sometimes called an "O-Ring", but it's not!)...these are the seals on the outside of the carb body that the throttle shaft passes through. Uses 2 per carb, BUT......without taking the carbs apart from the rack, the only ones you can replace are the outer seals on the #1 and the #4 carbs. Unlike the QR-series "o-rings" that many people recommend using---AND WHICH DO NOT FIT PROPERLY---these "V-Seals" do have the correct O.D., I.D., and thickness to fit both the throttle shaft and the carb shaft seal bore recess correctly. Used on all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.

HCP6838B OEM Mikuni throttle shaft V-SEAL, single:
$ 5.00

HCP6838BSET2 OEM Mikuni throttle shaft V-SEALS, pair:
$ 9.00

HCP6838BSET8 OEM Mikuni throttle shaft V-SEALS, set of 8:
$ 34.00


HCP38B Aftermarket Mikuni throttle shaft V-SEAL, single:
$ 3.75

HCP38BSET2 Aftermarket Mikuni throttle shaft V-SEALS, pair:
$ 7.00

HCP38BSET8 Aftermarket Mikuni throttle shaft V-SEALS, set of 8:
$ 25.00


COMMENTARY: These seals are a VERY common source of vacuum leaks into the carbs, making tuning (synch, colortune, etc.) somewhere between very difficult and next-to-impossible. And here's the dirty little secret that no one really talks about:

If you read through these boards often and enough---or any other websites or lists devoted to these XJ bikes----you'll find a common theme in regards to these bikes, and it goes something like this:

"My bike doesn't run right."

And 9 times out of 10, it's due to a carb problem. And to make matters worse, these bikes don't just use one carb, they use four, which means that the synchronization of the four carbs to each other is critical in order for them to perform properly.

And 95% of the problems with the carbs is this: they are dirty (more like filthy!) inside due to age, and these seals are worn out. But to replace these seals (and also to properly get the insides of the carbs absolutely, positively, ZESTFULLY! clean), you're gonna have to pull the carb rack apart. Although that task is not mechanically difficult....nor does it take any special tools to do it.....the re-assembly process will MERCILESSLY PUNISH the careless or impatient mechanic or hobbyist. A tremendous attention to detail and organization is needed before you begin to take these carbs apart, so that you will have all the proper notes, drawings, sketches, etc. to put humpty-dumpty back together again, properly.

Since most people lack those skills or discipline, you will find most of the experienced experts on the various boards and forums telling you to NOT take the carbs apart, and to forego the proper cleaning and parts replacement steps needed.

I'm not trying to tell you to do, or not to do the task properly yourself; all I can tell you is what my own personal experience is. If you have the proper tools, time, and organizational skills and the PATIENCE to do the job right, breaking a rack apart and doing the job properly isn't that difficult. If you don't, it's a nightmare.

And the other dirty little secret is this: before you can synch and tune your carbs properly, you MUST check and adjust your valve clearances (replace worn valve shims), or all the synching and colortuning in the world isn't going to give you optimal results.

Sorry to be the bearer of such bad news, but as always, the truth will set you free (or at least solve most of your tuning and performance issues!).

Luckily, all of the parts and special tools needed to perform a proper tune up ARE available. I guess we should appreciate the little things in life more than we usually do........



bbb) Aftermarket Mikuni carb Throttle Shaft Seal PLASTIC SHIM WASHER...these washers go directly "outside" of the throttle shaft seals listed above. Same notes as listed above about the seals (regarding the ease of replacement) also applies to these shims. NOTE: these shims do NOT "wear out" like the seals do; you only need to replace them if your shim washers are broken or missing. Used on all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.


HCP39C Aftermarket Mikuni throttle shaft seal SHIM WASHER, single:
$ 2.00

HCP39CSET2 Aftermarket Mikuni throttle shaft seal SHIM WASHERS, pair:
$ 3.75

HCP39CSET8 Aftermarket Mikuni throttle shaft seal SHIM WASHERS, eight shims:
$ 14.00





MIKUNI THROTTLE SHAFT HARDWARE:

ts5) Aftermarket Mikuni throttle shaft BUTTERFLY VALVE MOUNTING SCREW. Each round butterfly "valve" is held to the steel throttle shaft via two tiny phillips head screws. The throttle shaft has self-locking threads which makes the removal of these screws an absolute chore and usually results in a buggered phillips head slot. These replacement screws come in a variety of materials and drive styles. Use 2 per carb, 8 per entire carb rack. Used on all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.

NOTE: these screws are an absolute BEAST to remove, and it is very easy to destroy the screw heads as well as the throttle shaft threads while trying to remove them---if proper precautions are not taken. You will want to review the information in this forum thread before attempting removal:

http://www.xjbikes.com/Forums/viewtopic ... html#66348


For all of the above reasons, our recommendation is to use the allen-head (hex drive) style screws (HCP7120 or HCP7346 below) to make future removal easier. ALSO, since it is not really feasible to peen or stake the screws once installed (as Mikuni originally did---they must have had a special fixture to perform this task), it is strongly recommended that you use some type of semi-permanent thread-locking fluid (such as our HCP1266 or HCP1267 thread locker fluids) when installing these screws.....as the last thing you want to have happen is having these screws back out during engine operation.....as that would be a sad, sad day for you and your engine!


HCP5899 Aftermarket Mikuni butterfly valve MOUNTING SCREW, oval-head 18-8 stainless steel screw with a phillips-drive, each:
$ 1.00

HCP5899SET2 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, oval-head 18-8 stainless steel screw with a phillips-drive, set of 2:
$ 1.75

HCP5899SET8 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, oval-head 18-8 stainless steel screw with a phillips-drive, set of 8:
$ 5.00



HCP7120 Aftermarket Mikuni butterfly valve MOUNTING SCREW, flat-head 18-8 stainless steel socket head cap screw with a 2mm hex-drive, each:
$ 1.00

HCP7120SET2 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, flat-head 18-8 stainless steel socket head cap screw with a 2mm hex-drive, set of 2:
$ 1.95

HCP7120SET8 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, flat-head 18-8 stainless steel socket head cap screw with a 2mm hex-drive, set of 8:
$ 5.50



HCP7346 Aftermarket Mikuni butterfly valve MOUNTING SCREW, flat-head black-oxide coated alloy steel socket head cap screw with a 2mm hex-drive, each:
$ 1.00

HCP7346SET2 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, flat-head black-oxide coated alloy steel socket head cap screw with a 2mm hex-drive, set of 2:
$ 1.95

HCP7346SET8 Aftermarket Mikuni butterfly valve MOUNTING SCREWS, flat-head black-oxide coated alloy steel socket head cap screw with a 2mm hex-drive, set of 8:
$ 5.50



vv2) Aftermarket small parts NEEDLE FILES SET. This set of 12 miniature swiss files allows you to easily get into those tight spots with precise control. A variety of files----round, flat, triangle---all have easy-grip round knurled handles. Each file is approximately, 6" long. Works great for knocking the peening off the back of the original Mikuni throttle shaft screws before you attempt to remove them.

HCP9802 Aftermarket small parts NEEDLE FILES SET.
$ 14.95




ts5) OEM and aftermarket Mikuni carb throttle shaft retaining E-CLIP...these shaft retainer clips go directly "outside" of the plastic shim washers listed above on the #1 and #4 carbs only. Used on all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.


HCP6836 OEM throttle shaft end retaining E-CLIP, bright plated spring steel, each:
$ 3.50

HCP6836SET2 OEM throttle shaft end retaining E-CLIPS, set of 2:
$ 6.75


HCP905 Aftermarket throttle shaft end retaining E-CLIP, black-phosphate coated spring steel as original, each:
$ 1.00

HCP905SET2 Aftermarket throttle shaft end retaining E-CLIPS, set of 2:
$ 1.50


HCP2909 Aftermarket throttle shaft end retaining E-CLIP, type 420 stainless spring steel, each:
$ 1.75

HCP2909SET2 Aftermarket throttle shaft end retaining E-CLIPS, set of 2:
$ 3.00




MIKUNI IDLE MIXTURE SCREW PARTS:


NOTE: idle mixture screws are also referred to as "pilot mixture screws" or "pilot screws".

If you've never delved into the guts of your carburetor idle mixture screw port, it can sometimes be confusing. Here's the playbook for this critical area:

If we were looking at a cut-away of the carb body/idle mixture screw bore, the order of parts, from bottom to top, would be:

a) HCP895 o-ring
b) HCP896 spring seat washer
c) HCP6574 tension spring
d) the idle mixture screw
e) the metal anti-tamper cap.

What is mostly confusing is the order of the o-ring versus the spring seat washer....which goes in the hole first? The answer is that the HCP895 O-ring does. The HCP896 washer primarily acts as the lower "seat" for the HCP6574 tension spring, while also keeping the o-ring firmly and securely in place.



ims3) OEM Mikuni IDLE MIXTURE SCREW SET is correct for all original XJ550, XJ650 Turbo, XJ700-X, XJ750-X, and XJ900 carbs.

Each complete set contains one brass slot-headed idle mixture adjustment Screw, the mixture screw Spring, the spring Washer, and the sealing O-Ring. NOTE: the tension spring contained in this kit is not the correct length for the XJ650 Turbo, XJ900RK, or XJ1100 models, but will work.

HCP3745 OEM Mikuni IDLE MIXTURE SCREW SET....contains the brass idle mixture screw, spring, spring washer, and the o-ring. Each:
$ 16.95

HCP3745SET4 OEM Mikuni IDLE MIXTURE SCREW SETS, set of 4:
$ 64.95



ddd) Aftermarket Mikuni IDLE MIXTURE SCREW O-RING.....a "must-replace" item when rebuilding your carbs. Made of long-lasting, fuel-resistant Buna-N material.

HCP895 Aftermarket Mikuni idle mixture screw O-RING, fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, and XJ1100 carbs, each:
$ 1.00

HCP895SET4 Aftermarket Mikuni idle mixture screw O-RINGS, set of 4:
$ 3.00


eee) Aftermarket Mikuni IDLE MIXTURE SCREW SPRING SEAT WASHER.....also a "must-replace" item when rebuilding your carbs. Made of long-lasting, fuel- and water-resistant 18-8 stainless steel material.

HCP896 Aftermarket Mikuni idle mixture screw spring seat WASHER, fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900, and XJ1100 carbs, each:
$ 1.50

HCP896SET4 Aftermarket Mikuni idle mixture screw spring seat WASHERS, set of 4:
$ 5.00



ims6) Aftermarket carb IDLE MIXTURE SCREW TENSION SPRING, brand new reproductions exactly replace damaged, rusted, or missing originals. High-strength carbon-steel coil springs have a baked yellow-zinc plating as original.

HCP6574 Aftermarket reproduction idle mixture screw TENSION SPRING, fits Mikuni carbs used on all XJ550, XJ700-X, and XJ750-X models, each:
$ 3.50

HCP6574SET4 Aftermarket reproduction idle mixture screw TENSION SPRINGS, set of 4:
$ 10.95



HCP8544 Aftermarket reproduction idle mixture screw TENSION SPRING, fits Mikuni carbs used on all XJ650 Turbo, XJ900RK, and XJ1100 models, each:
$ 4.95

HCP8544SET4 Aftermarket reproduction idle mixture screw TENSION SPRINGS, set of 4:
$ 14.95




ims3) OEM and aftermarket idle mixture screw bore hole TAMPER CAPS, original round aluminum cap exactly replaces the original brass sealing cap and has the small breather hole in the center as original. Aftermarket rubber plug makes installation and removal a breeze, and is highly recommended as a replacement for the original style cap.

HCP3748 OEM Mikuni idle mixture screw bore hole aluminum TAMPER CAP, each:
$ 5.00

HCP3748SET4 OEM Mikuni idle mixture screw bore hole TAMPER CAPS, set of 4:
$ 19.00



HCP7376 Aftermarket Mikuni idle mixture screw bore hole RUBBER PLUG, tapered design with mushroom head allows repeated removal and re-use. NOTE: maybe a slightly loose fit on some models; if so, use a small amount of gasket or rubber adhesive to secure firmly in place (just a thin smear will do). Waterproof and dustproof design keeps the screw away from dirt and moisture, while also allowing for easy removal for tuning purposes. Each:
$ 4.50

HCP7376SET4 Aftermarket Mikuni idle mixture screw bore hole RUBBER PLUGS, set of 4:
$ 14.95




HCP254 Idle Mixture Screw REMOVAL AND ADJUSTER TOOL, fits all Mikuni idle mixture screws.
$ 17.95




MIKUNI IDLE SPEED SCREW PARTS:

Not to be confused with the idle MIXTURE screw listed above, the IDLE SPEED SCREW is the large knurled-head screw that lives dead center, at the bottom of the carb rack, in-between the #2 and #3 cars, and pointing straight back. This screw is used to adjust the idle speed of the engine, and has no effect on the idle mixture nor the carb (engine) "synch" settings!


HCP5161 OEM idle speed ADJUSTMENT SCREW AND SPRING SET, fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, and XJ900RK models.
$ 22.95


HCP9848 Aftermarket Mikuni idle speed screw rubber GROMMET, fits into the lower carb rack bracket opening where the idle speed screw enters the bracket. This replacement grommet is quite a bit larger than the stock grommet, but fits and works properly. Use a little bit of silicone grease on the screw's shaft where it passes through this grommet and it will be silky-smooth in operation. Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, and XJ900RK models
$ 1.95


HCP4024 Aftermarket Mikuni carb idle speed screw WASHER, not an original part, but if you use a set of these thin flat plastic shimming washers in-between the spring and the screw, and between the spring and the bracket (in other words, on either end of the spring), it greatly reduces the friction between the two and makes the idle screw silky-smooth to adjust! Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models Each:
$ 0.75




MIKUNI CARB STARTER-ENRICHMENT CIRCUIT-CHOKE SYSTEM PARTS:

The starter (choke) circuit is prone to a number of problems, from clogged passages in the starter jet (down int he bowl) to worn or fractured plunger valves and their related hardware. We've got some of those hard-to-find parts to properly restore your system.

The starter circuit PLUNGER VALVES are the solid brass needle-tip valve that actually shuts off or opens the enrichment circuit. Worn tips or fractured heads renders these valves useless. These valves are SPRING-loaded, and retained in the starter valve port in the carb body by a threaded, hollow-center brass SEAT, which is then surrounded by a small rubber DUST CAP. In addition, XJ650 Turbo models used a rubber O-RING to provide an air-tight seal at the cover-to-carb body mating surface.


HCP5197 OEM Mikuni brass PLUNGER VALVE, fits all XJ550 models, each:
$ 16.25

HCP9933 OEM Mikuni brass PLUNGER VALVE, fits all XJ650 Turbo, XJ700-X, and XJ750-X models, each:
$ 27.95




HCP5198 OEM Mikuni brass plunger valve SPRING, fits all XJ550, XJ650 Turbo, XJ700-X and XJ750-X models, each:
$ 5.95




HCP9334 OEM Mikuni brass plunger valve threaded brass SEAT, fits all XJ550, XJ700-X and XJ750-X models, each:
$ 9.95



HCP9846 Aftermarket starter circuit plunger valve seat O-RING, correct for the XJ650 Turbo models (o-rings were only used in this area on Turbo carbs). Fits just under the head of the threaded plunger shaft cap. Each:
$ 1.50

HCP9846SET4 Aftermarket starter circuit plunger seat O-RINGS, correct for the XJ650 Turbo models (o-rings were only used in this area on Turbo carbs), set of 4:
$ 5.00



HCP9335 OEM Mikuni brass plunger valve threaded brass seat DUST CAP, fits all XJ550, XJ650 Turbo, XJ700-X, and XJ750-X models, each:
$ 6.95



HCP9895 OEM Mikuni brass PLUNGER VALVE SET, contains the brass plunger Valve, the Spring, the threaded brass Seat, and the rubber seat Cap. Fits all XJ650 Turbo, XJ700-X, and XJ750-X models. NOTE: the threaded brass seat that comes with this set is not correct and will not fit the XJ650 Turbo models. Each:
$ 44.95



MIKUNI FUEL AND AIR JETS:


MIKUNI MAIN FUEL JETS:


ee) OEM and aftermarket Mikuni brass MAIN FUEL JETS, sizes as follows, fits all XJ550, XJ650 Turbo, all XJ700-X and XJ750-X, XJ900RK, and XJ1100 models.

NOTE: stock Mikuni XJ series carbs used the following original main fuel jet sizes:

#100 1985 all XJ700-X models
#102.5 XJ900RK US & Canada
XJ550L (1984) on cylinders #3 and #4
#105 1986 all XJ700-X models and all XJ750-X
XJ550L (1984) on cylinders #1 and #2
#107.5 XJ900 1983-84 except USA or Canada
#112.5 XJ550 all models and XJ1100
#127.5 XJ650 Turbo carbs for cylinders #1 and #4**
#132.5 XJ650 Turbo carbs for cylinders #2 and #3**

**NOTE: there is conflicting information between original and re-printed service manuals and the factory parts manuals concerning the size of the main jets for the XJ650 Turbo models. We have tried to provide the most accurate information available to us above. Some manuals call for the use of #125 main fuel jets on the #1 and #4 carbs, some call for the use of #130 main fuel jets on the #1 and #4 carb, and a #135 main fuel jet on the #2 and #3 carbs. What we believe to be correct is the #127.5/#132.5 combination of jet sizes as listed above.

All the other sizes are for "tuning" or re-jetting purposes when changing intakes or exhaust systems.


HCP6900 OEM Mikuni MAIN FUEL JET #105
HCP6901 OEM Mikuni MAIN FUEL JET #107.5
HCP6902 OEM Mikuni MAIN FUEL JET #110
HCP6903 OEM Mikuni MAIN FUEL JET #112.5
HCP6904 OEM Mikuni MAIN FUEL JET #115
HCP6905 OEM Mikuni MAIN FUEL JET #117.5
HCP6906 OEM Mikuni MAIN FUEL JET #120
HCP6908 OEM Mikuni MAIN FUEL JET #125
HCP6909 OEM Mikuni MAIN FUEL JET #127.5
HCP6910 OEM Mikuni MAIN FUEL JET #130
HCP6911 OEM Mikuni MAIN FUEL JET #132.5
HCP6912 OEM Mikuni MAIN FUEL JET #135
HCP6913 OEM Mikuni MAIN FUEL JET #137.5
HCP6914 OEM Mikuni MAIN FUEL JET #140
HCP6915 OEM Mikuni MAIN FUEL JET #142.5
HCP6916 OEM Mikuni MAIN FUEL JET #145
HCP6917 OEM Mikuni MAIN FUEL JET #147.5
HCP6918 OEM Mikuni MAIN FUEL JET #150

All of the above OEM Mikuni Main Fuel Jets are priced as follows:
$ 5.50 each
or
$ 18.00 per set of 4


HCP6919 Aftermarket Mikuni MAIN FUEL JET #90
HCP6920 Aftermarket Mikuni MAIN FUEL JET #95
HCP6921 Aftermarket Mikuni MAIN FUEL JET #100
HCP6922 Aftermarket Mikuni MAIN FUEL JET #102.5
HCP6923 Aftermarket Mikuni MAIN FUEL JET #105
HCP6924 Aftermarket Mikuni MAIN FUEL JET #107.5
HCP6925 Aftermarket Mikuni MAIN FUEL JET #110
HCP6926 Aftermarket Mikuni MAIN FUEL JET #112.5
HCP6927 Aftermarket Mikuni MAIN FUEL JET #115
HCP6928 Aftermarket Mikuni MAIN FUEL JET #117.5
HCP6929 Aftermarket Mikuni MAIN FUEL JET #120
HCP6930 Aftermarket Mikuni MAIN FUEL JET #122.5
HCP6931 Aftermarket Mikuni MAIN FUEL JET #125
HCP6932 Aftermarket Mikuni MAIN FUEL JET #127.5
HCP6933 Aftermarket Mikuni MAIN FUEL JET #130
HCP6934 Aftermarket Mikuni MAIN FUEL JET #135
HCP6936 Aftermarket Mikuni MAIN FUEL JET #140
HCP6937 Aftermarket Mikuni MAIN FUEL JET #142.5
HCP6938 Aftermarket Mikuni MAIN FUEL JET #145
HCP6939 Aftermarket Mikuni MAIN FUEL JET #147.5
HCP6940 Aftermarket Mikuni MAIN FUEL JET #150
HCP6941 Aftermarket Mikuni MAIN FUEL JET #152.5
HCP6942 Aftermarket Mikuni MAIN FUEL JET #155
HCP6943 Aftermarket Mikuni MAIN FUEL JET #157.5
HCP6944 Aftermarket Mikuni MAIN FUEL JET #160
HCP6945 Aftermarket Mikuni MAIN FUEL JET #165
HCP6946 Aftermarket Mikuni MAIN FUEL JET #170
HCP6947 Aftermarket Mikuni MAIN FUEL JET #175
HCP6948 Aftermarket Mikuni MAIN FUEL JET #180

All of the above Aftermarket Mikuni Main Fuel Jets are priced as follows:
$ 2.50 each
or
$ 9.75 per set of 4




MIKUNI MAIN AIR JETS:

Alas, the Mikuni BSxx series carbs used on XJ models---unlike their cousins the Hitachi HSCxx series carbs---did not have replaceable main jets. The main air jets on these models are in the carb throat, facing the airbox, and are a small, brass pressed-in tube that is non replaceable, and which we suggest you do NOT try to modify by drilling or enlarging.

And just in case anyone is wondering, here are the sizes of these non-removable main air jets in the various models:

#45: XJ900RK
#70: XJ550 all models and XJ650 Turbo models.
#120: XJ700-X all models and XJ750-X all models*
#140: XJ1100 models*

NOTE: we believe that the #120 and #140 sizes listed in the service manuals (from where the above information was gathered) may be incorrect, as these are gigantic sizes for main air jets. But since you can't replace them anyway, I suppose that it doesn't really matter........




MIKUNI PILOT FUEL JETS:

ef) OEM and aftermarket Mikuni brass PILOT FUEL JETS, sizes as follows, fits all XJ550, XJ650 Turbo, all XJ700-X and XJ750-X, XJ900RK, and XJ1100 models.

NOTE: stock Mikuni XJ series carbs used the following original pilot fuel jet sizes:

#32.5 XJ650LK Turbo (1983)
#35 XJ550 all models, XJ650LJ Turbo (1982), and XJ700-X all models
#37.5 XJ750-X and XJ900RK USA & Canada only
#40 XJ900 1983-84 except USA or Canada
#47.5 XJ1100


All the other sizes are for "tuning" or re-jetting purposes when changing intakes or exhaust systems.


HCP5223 OEM Mikuni PILOT FUEL JET #32.5
$ 15.00 each
or
$ 55.00 set of 4

HCP5183 OEM Mikuni PILOT FUEL JET #35
$ 15.00 each
or
$ 55.00 set of 4

HCP6890 OEM Mikuni PILOT FUEL JET #37.5
$ 14.00 each
or
$ 51.00 set of 4

HCP6889 OEM Mikuni PILOT FUEL JET #47.5
$ 16.50 each
or
$ 59.00 set of 4



HCP6949 Aftermarket Mikuni PILOT FUEL JET #30
HCP6950 Aftermarket Mikuni PILOT FUEL JET #32.5
HCP6951 Aftermarket Mikuni PILOT FUEL JET #35
HCP6952 Aftermarket Mikuni PILOT FUEL JET #37.5
HCP6953 Aftermarket Mikuni PILOT FUEL JET #40
HCP6954 Aftermarket Mikuni PILOT FUEL JET #42.5
HCP6955 Aftermarket Mikuni PILOT FUEL JET #45
HCP6956 Aftermarket Mikuni PILOT FUEL JET #47.5
HCP6957 Aftermarket Mikuni PILOT FUEL JET #50
HCP6958 Aftermarket Mikuni PILOT FUEL JET #52.5
HCP6959 Aftermarket Mikuni PILOT FUEL JET #55

All of the above Aftermarket Mikuni Pilot Fuel Jets are priced as follows:
$ 4.50 each
or
$ 14.00 per set of 4




MIKUNI PILOT AIR JETS:

Pilot air jets on the Mikuni BSxx series carbs are replaceable and are located under the diaphram cover on all XJ550 models, and XJ650 Turbo models, and in the carb throat, facing the airbox, on all XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.


ef) OEM and aftermarket Mikuni brass PILOT AIR JETS, sizes as follows, fits all XJ550, XJ650 (except Turbo), all XJ700-X and XJ750-X, XJ900RK, and XJ1100 models.

NOTE: stock Mikuni XJ series carbs used the following original pilot air jet sizes:

#120 XJ750-X models
#140 XJ700-X and XJ750-X models
#155 XJ550L (1984) models
#160 XJ900RK all models
#165 XJ550 Maxim models (1981-83)
#170 XJ550 Seca models, XJ650 Turbo, and XJ1100

All the other sizes are for "tuning" or re-jetting purposes when changing intakes or exhaust systems.


HCP5218 OEM Mikuni PILOT AIR JET #155
$ 8.50 each
or
$ 32.00 set of 4


HCP6892 OEM Mikuni PILOT AIR JET #160
$ 8.00 each
or
$ 30.00 set of 4


HCP5206 OEM Mikuni PILOT AIR JET #165
$ 6.50 each
or
$ 24.00 set of 4


HCP5171 OEM Mikuni PILOT AIR JET #170
$ 8.00 each
or
$ 30.00 set of 4



HCP6960 Aftermarket Mikuni PILOT AIR JET #110
HCP6961 Aftermarket Mikuni PILOT AIR JET #112.5
HCP6962 Aftermarket Mikuni PILOT AIR JET #115
HCP6963 Aftermarket Mikuni PILOT AIR JET #117.5
HCP6964 Aftermarket Mikuni PILOT AIR JET #120
HCP6965 Aftermarket Mikuni PILOT AIR JET #122.5
HCP6966 Aftermarket Mikuni PILOT AIR JET #125
HCP6967 Aftermarket Mikuni PILOT AIR JET #130
HCP6968 Aftermarket Mikuni PILOT AIR JET #135
HCP6969 Aftermarket Mikuni PILOT AIR JET #137.5
HCP6970 Aftermarket Mikuni PILOT AIR JET #140
HCP6971 Aftermarket Mikuni PILOT AIR JET #142.5
HCP6972 Aftermarket Mikuni PILOT AIR JET #145
HCP6973 Aftermarket Mikuni PILOT AIR JET #147.5
HCP6974 Aftermarket Mikuni PILOT AIR JET #150


All of the above Aftermarket Mikuni Pilot Air Jets are priced as follows:
$ 2.50 each
or
$ 9.50 per set of 4



WHAT ABOUT RE-JETTING FOR PODS, ETC?:

It's a question we get asked often and unfortunately, one that we cannot answer honestly about your specific bike besides with "it depends".

Which is a nice way of saying "you're about to enter the seventh circle of hell......."!

Carb jet tuning required by aftermarket modifications is somewhat of a black art, part science, part skill, part luck. It depends on the current state of tune of your engine, your altitude, the mix of aftermarket parts on your bike, etc........a lot of variables.

The best advice we can offer is: Just Say No. Don't do it! Leave everything stock!

But, since most people---with good reason, I might add---don't always listen to our well-intentioned advice, then the next best recommendation we can offer is: "if you want more power get a bigger bike!".

And since that doesn't cut it with many owners, either, for the remaining stalwarts out there who insist on "experimenting" with aftermarket intake and exhaust systems, here's the best information that we've come across to give you some GUIDANCE, which you should take as just that, and not as ANSWERS, because it isn't!



MAIN FUEL JET SIZE CHANGES NEEDED PER TYPICAL MODIFICATION:


Typical Exhaust Changes:

+2 main fuel jet size for custom 4-into-2 exhaust

or

+4 main fuel jet sizes for 4-into-1 exhaust

or

+4 main jet sizes for no muffler (open headers)


Typical Intake Changes:

+2 main fuel jet sizes for single K&N filter (inside a stock airbox)

or

+2 main fuel jet size for drilling holes in the airbox with stock filter

or

+4 main fuel jet sizes for individual pod filters (no airbox)



Additional changes:

- Add up all the main fuel jet size increases and subtract 2 sizes.

- Decrease main fuel jet size by 2 sizes per every 2000' above sea level.

- Under a mis-match condition, such as when using pod filters with a 100% stock exhaust, or 4-into-1 header with stock filter and air box, then subtract 2 main fuel jet sizes.


PILOT FUEL JET SIZES CHANGES NEEDED PER TYPICAL MODIFICATION:

Pilot fuel jet size changes are related only to the change in main fuel jet sizes according to the main fuel jet size formula described above. Note that this pilot fuel jet rule is for the main fuel jet size change BEFORE any main fuel jet altitude compensation is factored in:

Increase the pilot fuel jet size +1 for every +3 main fuel jet size increases.

Additional changes:

- Decrease pilot fuel jet size by 1 for every 6000' above sea level.



PRECAUTIONS:

- Make sure your carbs are in perfect working order before making jet changes....meaning fully cleaned internally and rebuilt, operating properly in their stock configuration, proper sized air jets and needles, etc.

- Check plug color often and adjust as needed, 2 main fuel jet sizes at a time and 1 pilot fuel jet size at a time. Bright white plug insulators are a sign of an overly lean fuel mixture condition and WILL cause damage to your engine over time, up to and including engine seizure!

- Synch the carbs after each jet change.

- Make sure the floats are set correctly

- Seriously consider purchasing a Colortune Plug Tuning kit.

- You may find it necessary to make changes to the size or shimming of the main jet needle. There are no guidelines on what or how to do these changes, this is true trial-and-error tuning!



EXAMPLE:

A 1982 XJ550RJ Seca using an aftermarket Supertrapp 4-into-1 exhaust and a single K&N air filter in the stock, unmodified airbox. Bike is primarily operated at an altitude of 2600 feet above sea level.

XJ550 Seca Stock Mikuni BS28-series Carb Jetting:

#112.5 Main Fuel Jet
#35 Pilot Fuel Jet
#70 Main Air Jet
#170 Pilot Air Jet
4GZ11 Needle


MAIN FUEL JET SIZE CALCULATIONS:

Changes made:

Exhaust:
4 into 1 with Supertrapp = +4 Sizes Main Fuel Jet

Intake:
K&N Pod Filters = +4 sizes Main Fuel Jet
----------------------------
Equals: +8 main fuel jet sizes above baseline
Subtract: -2 main fuel jet size per formula above
----------------------------
Equals: +6 main fuel jet sizes due to modifications, thus:

Stock main fuel jet size is: #112.5
+ 6 additional sizes
= a #118.5 main fuel jet size
---------------------------
Subtract: -2 main fuel jet sizes for Altitude of 2500' Average

= #118.5 calculated from above
-2 jet sizes for altitude adjustment

= a #116.5 main fuel jet size.


PILOT FUEL JET SIZE CALCULATIONS:

The formula is: +1 pilot jet size increase for every +3 main jet sizes increased.

Stock pilot fuel jet size is: #35
+ 2 additional jet sizes (since we went up +6 main fuel jet sizes before the altitude compensation was factored in):

= a #37 pilot fuel jet size.

Note that no altitude compensation is needed on the pilot fuel jet since our elevation is less than 6000' a-s-l.


------------------------------

RESULT:

A #116.5 Main Fuel Jet and #37 Pilot Fuel Jet is A GOOD STARTING POINT.

******************************************************

Note that the above calculations do NOT take into account any possible changes in the sizes of the air jets nor the main needle size, which are additional variables and opportunities for tuning excellence (or frustration!).

For further insights and understanding, the Holy Grail (meaning: the whole miserable, un-varnished truth of what a real chore carb tuning is going to be, written by people who actually know what they're talking about, rather than by people who are trying to sell you something) can be found at:

www.factorypro.com

and then click on the "Product Support/Technical Support" link at the top of the page, then on the "Motorcycle Tuning Tech" link, and then the "CV Carb Tuning" link........and then read, weep, study, and do....if you still dare to! As you will soon realize, it's takes quite a bit of effort to properly tune a carb to its optimal performance----another reason why we don't suggest using pods!




MIKUNI MAIN JET NEEDLES:

mjw1) Aftermarket Mikuni main jet needle TUNING WASHERS, these precision ground 18-8 stainless steel shim washers are used to raise the main jet needle height slightly, in order to allow performance tuning modifications when the stock intake or exhaust system has been modified. Tuning washers fit on top of the plastic needle cap and underneath the needle cap clip. Each washer is .025mm thick, and multiple washers can be used to provide the proper tuning desired. Fits all XJ550, 650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models.


HCP7142 aftermarket 18-8 stainless steel TUNING WASHER, each:
$ 1.95

HCP7142SET4 aftermarket 18-8 stainless steel TUNING WASHERS, set of 4:
$ 6.00

HCP7142SET8 aftermarket 18-8 stainless steel TUNING WASHERS, set of 8:
$ 10.00

HCP7142SET12 aftermarket 18-8 stainless steel TUNING WASHERS, set of 12:
$ 12.00




MIKUNI MAIN JET NOZZLE OR EMULSION TUBE:

Called by a variety of names, the main fuel jet tube is technically known as the MAIN NOZZLE, although they also go by the name of "power valves", "emulsion tubes", or some choice four-letter words whie you are trying to remove them from their bore hole in the carb body! These 2-3" long tubes have a series of very precise, very small holes that actually pass the fuel from the main fuel jet around the jet needle, and are what provide the final, precise metering of the fuel mixture through the main jet.

Commonly clogged and dirty-filthy beyond belief, they are easy to damage while removing them or during the cleaner process. If the holes are enlarged, or the threads in the jet end damaged, these nozzles should be replaced, or your bike will never run properly.


HCP5224 OEM Mikuni brass MAIN NOZZLE, fits all XJ650 Turbo models, each:
$ 39.00

HCP5224SET4 OEM Mikuni brass MAIN NOZZLE, fits all XJ650 Turbo models, set of 4:
$ 149.95




HCP9899 OEM Mikuni brass MAIN NOZZLE, fits all XJ900RK models, each:
$ 39.00

HCP9899SET4 OEM Mikuni brass MAIN NOZZLE, fits all XJ900RK models, set of 4:
$ 149.95





MIKUNI CARB BOWL PARTS:


ii) OEM and aftermarket Mikuni FLOAT BOWL GASKETS & O-RINGS:

Die-cut replacement carb bowl-to-carb body gaskets correctly replace your torn or leaking originals. Note that the XJ650 Turbo body used a shape-molded o-ring in place of a standard paper gasket.



For XJ550 models:

HCP5182 OEM Mikuni carb FLOAT BOWL GASKET, each:
$ 4.75

HCP5182SET4 OEM Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 17.95


HCP863 Aftermarket Mikuni carb FLOAT BOWL GASKET, each:
$ 4.00

HCP863SET4 Aftermarket Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 13.00


For XJ650 Turbo models:

HCP5222 OEM carb bowl-to-body rubber FLOAT BOWL O-RING, for all XJ650 Turbo models, each:
$ 13.95

HCP5222SET4 OEM carb FLOAT BOWL O-RINGS, set of 4:
$ 54.00



For XJ700 "X", XJ750-X, and XJ900RK models:

HCP8563 OEM Mikuni carb FLOAT BOWL GASKET, each:
$ 7.50

HCP8563SET4 OEM Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 27.00


HCP1674 Aftermarket Mikuni carb FLOAT BOWL GASKET, each:
$ 4.00

HCP1674SET4 Aftermarket Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 13.00



For XJ1100 models:

HCP6575 OEM Mikuni carb FLOAT BOWL GASKET, each:
$ 14.95

HCP6575SET4 OEM Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 57.00


HCP1675 Aftermarket Mikuni carb FLOAT BOWL GASKET, each:
$ 4.00

HCP1675SET4 Aftermarket Mikuni carb FLOAT BOWL GASKETS, set of 4:
$ 13.00


Okay, everyone asks, so here goes: should you use the OEM Yamaha or the aftermarket bowl gaskets? Well, the OEM Yamaha gaskets look and feel more substantial, and have a somewhat waxy coating to them, which is there for a reason I suppose---probably has to do with the longevity of the gasket when the float bowls are being removed and replaced quite often. HOWEVER, I've used both the OEM and the replacement bowl gaskets on my own bikes and carb sets and have never had either style leak. I make more money selling the aftermarket gaskets, but for the small difference in price, if you're not on an ultra-tight budget, I'd use the OEM gaskets on my own personal bikes..........just my thoughts.

ALSO: if you use any type of sealant on these gaskets, use it on the BOWL side of the gasket (something like Permatex Copper Spray-A-Gasket is a fine choice). On the carb body side of the gasket, use a light oil....like Marvel Mystery Oil or the like....and barely moisten the gasket surface. This will allow the new gasket to soften slightly and allows the gasket to form itself to the raised mounting ridge that is cast onto the carb body mating flange.....and also allows for an easy, no-stick removal of the float bowl in the future!




MIKUNI CARB FLOATS AND FLOAT NEEDLE VALVES:

fs4) Aftermarket Mikuni float valve NEEDLE ONLY...for those who wish to do an extreme-budget rebuild, you can buy the rubber-tipped float valve needle by itself (without its brass seat).

For use on all XJ550 models, all XJ700-X and XJ750-X models, all XJ900RK models with the clipped-to-the-float style seat, and all XJ1100 models:

HCP1670 Aftermarket Mikuni float valve NEEDLE with retainer clip, each:
$ 8.50

HCP1670SET4 Aftermarket Mikuni float valve NEEDLES with retainer clip, set of 4:
$ 29.00


For use on all XJ650 Turbo, and all XJ900RK models with the non-clipped to the float style of needle/seat:

HCP1671 Aftermarket Mikuni float valve NEEDLE only, each:
$ 4.50

HCP1671SET4 Aftermarket Mikuni float valve NEEDLES only, set of 4:
$ 17.00




kk) OEM and Aftermarket Mikuni FLOAT NEEDLE VALVE ASSEMBLY---contains the float needle with retainer clip (if used), float valve brass seat, the seat o-ring, and the seat filter screen.

NOTE: XJ900RK models can use either a valve with a 2.0mm seat opening and which uses a non-clipped-to-the-float needle style, or they can use a valve with a larger 2.3mm seat opening and which uses a clipped-to-the-float style of needle. THE TWO STYLES ARE NOT INTERCHANGEABLE---you cannot use one style seat with the other style needle. You CAN, however, interchange the complete needle/seat units on all XJ900RK (Mikuni BS33 series) carbs. However, you should use all four of the same style in a complete set of carbs. Generally speaking, we've seen the non-clipped needle and seat style valves (with the 2.0mm valve seat orifice) used mostly on North American models, and the clipped needle and seat style valves (with the 2.3mm valve seat orifice) used on the non-North American models.



HCP5191 OEM single FLOAT NEEDLE VALVE ASSEMBLY, fits all XJ550 and XJ1100 carbs, each:
$ 28.00

HCP5191SET4 OEM FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 99.00



HCP1672 Aftermarket single FLOAT NEEDLE VALVE ASSEMBLY, fits all XJ550 and XJ1100 carbs, each:
$ 29.95

HCP1672SET4 Aftermarket FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 109.00



HCP5229 OEM single FLOAT NEEDLE VALVE ASSEMBLY, for all XJ650 Turbo models. Each:
$ 66.00

HCP5229SET4 OEM FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 249.00



HCP8562 OEM single FLOAT NEEDLE VALVE ASSEMBLY, for all XJ700-X, XJ750-X. Also fits the XJ900RK with the 2.3mm orifice and the clipped-to-the-float style needle. Each:
$ 59.95

HCP8562SET4 OEM FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 229.00



HCP1673 Aftermarket single FLOAT NEEDLE VALVE ASSEMBLY, for all XJ700-X, XJ750-X. Also fits the XJ900RK with the 2.3mm orifice and the clipped-to-the-float style needle. Each:
$ 16.00

HCP1673SET4 Aftermarket FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 57.00



HCP8560 OEM single FLOAT NEEDLE VALVE ASSEMBLY, for all XJ900RK models with a 2.0mm seat orifice and non-clipped-to-the-float style needle, each:
$ 65.00

HCP8560SET4 OEM FLOAT NEEDLE VALVE ASSEMBLIES, set of 4:
$ 229.00



fnv1) OEM and aftermarket Mikuni float needle valve SEAT O-RING. These o-rings are included in the replacement float needle valve assemblies listed above; but, if you want to re-use your original valve seats, we still recommend the replacement of the seat-to-carb body o-rings.


HCP5192 OEM Mikuni float needle valve SEAT O-RING, tough and durable buna-N material. Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models. Each:
$ 3.50

HCP5192SET4 OEM Mikuni float needle valve SEAT O-RING, tough and durable buna-N material, set of 4:
$ 10.50



HCP7406 Aftermarket Mikuni float needle valve SEAT O-RING, tough and durable buna-N material. Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models. Each:
$ 1.50

HCP7406SET4 Aftermarket Mikuni float needle valve SEAT O-RING, tough and durable buna-N material, set of 4:
$ 4.50



fnv2) OEM and aftermarket Mikuni float needle valve SEAT FILTER SCREEN. These small domed mesh screen filters snap onto the top of the float needle valve seat and help to keep crud, junk, and other kinds of cosmic debris out of the carbs. These filter screens are included in the replacement float needle valve assemblies and lower end rebuild kits listed above; but, if you want to re-use your original valve seats, we still recommend the replacement of these screens. Fits all XJ550, XJ650 Turbo, XJ700-X and XJ750-X models, XJ900RK, and XJ1100 models.


HCP5193 OEM Mikuni float valve needle SEAT FILTER SCREEN, use one per carb, each:
$ 8.50

HCP5193SET4 OEM Mikuni float valve needle SEAT FILTER SCREEN, use one per carb, set of 4:
$ 32.00



HCP2735 Aftermarket Mikuni float valve needle SEAT FILTER SCREEN, use one per carb, each:
$ 8.00

HCP2735SET4 Aftermarket Mikuni float valve needle SEAT FILTER SCREEN, use one per carb, set of 4:
$ 28.00



fh4) OEM and Aftermarket Mikuni float valve mounting bracket RETAINING SCREW. Original screws are panhead, phillips drive alloy steel and strip out easily. Our original and aftermarket replacement screws prevent future problems....it's a good idea to replace these whenever you remove your float needle valve seats. Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models. Use 1 per carb.

HCP5187 OEM Mikuni float valve mounting bracket RETAINING SCREW, panhead phillips-drive alloy steel, each:
$ 1.00

HCP5187SET4 OEM Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 2.75



HCP6708 Aftermarket Mikuni float valve mounting bracket RETAINING SCREW, panhead phillips-drive zinc-plated alloy steel, each:
$ 0.50

HCP6708SET4 Aftermarket Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 1.75



HCP6709 Aftermarket Mikuni float valve mounting bracket RETAINING SCREW, panhead phillips-drive 18-8 stainless steel, bright finish, each:
$ 1.00

HCP6709SET4 Aftermarket Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 3.00



HCP6710 Aftermarket Mikuni float valve mounting bracket RETAINING SCREW, panhead phillips-drive 18-8 stainless steel, black-oxide coated finish, each:
$ 1.25

HCP6710SET4 Aftermarket Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 3.50



HCP6712 Aftermarket Mikuni float valve mounting bracket RETAINING SCREW, socket head cap screw, hex-drive, 18-8 stainless steel, bright finish, each:
$ 1.00

HCP6712SET4 Aftermarket Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 2.50



HCP6711 Aftermarket Mikuni float valve mounting bracket RETAINING SCREW, socket head cap screw, hex-drive, 18-8 stainless steel, black-oxide coated finish, each:
$ 1.00

HCP6711SET4 Aftermarket Mikuni float valve mounting bracket RETAINING SCREWS, set of 4:
$ 2.50




fs8) OEM and aftermarket Mikuni carb fuel bowl FLOAT and FLOAT PIN, brand new replacement units.


HCP5188 OEM Mikuni FLOAT, float only (pin is not included and must be ordered separate), fits all XJ550 and XJ650 Turbo models, each:
$ 27.95

HCP5188SET4 Mikuni FLOATS, set of 4:
$ 104.95



HCP9940 Aftermarket Mikuni FLOAT and FLOAT PIN SET, fits all XJ550 and XJ650 Turbo models, each:
$ 21.00

HCP9940SET4 Mikuni FLOAT and FLOAT PIN SETS, set of 4:
$ 79.95



HCP9944 OEM Mikuni FLOAT, float only (pin is not included and must be ordered separate), fits all XJ700-X, XJ750-X, XJ900RK, and all XJ1100 models, each:
$ 27.95

HCP9944SET4 Mikuni FLOATS, set of 4:
$ 104.95



HCP1668 Aftermarket Mikuni FLOAT and FLOAT PIN SET, fits all XJ700-X, XJ750-X, XJ900RK, and all XJ1100 models, each:
$ 27.00

HCP1668SET4 Mikuni FLOAT and FLOAT PIN SETS, set of 4:
$ 102.00




HCP5190 OEM Mikuni FLOAT PIN, fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and all XJ1100 models, each:
$ 2.95

HCP5190SET4 OEM Mikuni FLOAT PINS, set of 4:
$ 10.95



oo) Aftermarket Mikuni carb LOWER END REBUILD KIT---contains the float needle with retainer clip, float valve brass seat with the filter screen, the seat o-ring, the idle mixture screw block-off cap, the idle mixture screw o-ring (which is the wrong size----it's way too fat, but it's in there anyway!), a bowl drain screw o-ring, and a reproduction bowl gasket.



XJ550 models:

HCP1669 Aftermarket Mikuni carb LOWER END REBUILD KIT, each:
$ 19.00

HCP1669SET4 Aftermarket Mikuni carb LOWER END REBUILD KITS, set of 4:
$ 69.00



MIKUNI CARB VACUUM DIAPHRAM AND PISTON UNITS:

fs6) OEM and aftermarket Mikuni carb VACUUM DIAPHRAM AND PISTON ASSEMBLY, the slide piston with the non-detachable rubber vacuum diaphram seal. Although it is possible to repair TINY pin-holes that occur in original diaphrams, anything greater than that will require replacement, as these diaphram are under a lot of pressure and stress and the continued flexing of the rubber will eventually lead to failure.


HCP5174 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLY, fits all XJ550 models, each:
$ 149.00

HCP5174SET4 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLIES, set of 4:
$ 549.00



HCP7118 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLY, fits all XJ700-X and XJ750-X models, each:
$ 144.00

HCP7118SET4 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLIES, set of 4:
$ 539.00



HCP7117 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLY, fits all XJ900RK and XJ1100 models, each:
$ 119.00

HCP7117SET4 OEM Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLIES, set of 4:
$ 429.00



HCP1667 Aftermarket Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLY, fits all XJ900RK and XJ1100 models, each:
$ 99.00

HCP1667SET4 Aftermarket Mikuni VACUUM DIAPHRAM AND PISTON ASSEMBLIES, set of 4:
$ 339.00



bb3) HCP8540 Aftermarket carb diaphram rubber RnR FLUID. Dissolved and chlorinated paraffin wax is the best (and perhaps the only) way to safely bring some life back into stiff, worn rubber material... such as that found in those all-important carb piston diaphrams. Years of hard life inside of your carb take their toll, and whenever your carb is apart for service, and generous application of this product will help to clean, maintain, and restore the flexibility, while prolonging their usable service life. 10cc dripper bottle contains enough fluid to do about eight diaphrams. Simple to use, spread on, wait a few seconds, wipe off, repeat and you're done!
$ 9.95



fms7) OEM and aftermarket Mikuni carb vacuum diaphram-piston assembly spring seat MOUNTING SCREW, panhead phillips-drive screws secures the round spring seat plate to the bottom of the diaphram assembly. Fits all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models. NOTE: the original screws on XJ550 and XJ650 Turbo models did NOT use a lockwasher; all others did use integral lock washers. Replacement screws listed below do not have integral lockwashers, and they can be ordered separate below. Use 2 per carb.


HCP5175 OEM Mikuni carb vacuum piston spring seat MOUNTING SCREW, yellow zinc-plated alloy steel, panhead, phillips-drive screw, each:
$ 1.00

HCP5175SET2 OEM Mikuni carb vacuum piston spring seat MOUNTING SCREWS, yellow zinc-plated alloy steel, panhead, phillips-drive screw, set of 2:
$ 1.90

HCP5175SET8 OEM Mikuni carb vacuum piston spring seat MOUNTING SCREWS, yellow zinc-plated alloy steel, panhead, phillips-drive screw, set of 8:
$ 6.00



HCP2907 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREW, zinc-plated alloy steel, panhead, phillips-drive screw, each:
$ 0.75

HCP2907SET2 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, zinc-plated alloy steel, panhead, phillips-drive screw, set of 2:
$ 1.25

HCP2907SET8 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, zinc-plated alloy steel, panhead, phillips-drive screw, set of 8:
$ 3.50



HCP105 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREW, 18-8 bright stainless steel, panhead, phillips-drive screw, each:
$ 1.50

HCP105SET2 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, 18-8 bright stainless steel, panhead, phillips-drive screw, set of 2:
$ 2.50

HCP105SET8 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, 18-8 bright stainless steel, panhead, phillips-drive screw, set of 8:
$ 7.50



HCP2908 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREW, black oxide coated alloy steel, panhead, phillips-drive screw, each:
$ 1.50

HCP2908SET2 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, black oxide coated alloy steel, panhead, phillips-drive screw, set of 2:
$ 2.50

HCP2908SET8 aftermarket Mikuni carb vacuum piston spring seat MOUNTING SCREWS, black oxide coated alloy steel, panhead, phillips-drive screw, set of 8:
$ 7.50



HCP7119 aftermarket Mikuni carb vacuum piston spring seat screw LOCK WASHER, 18-8 stainless steel, each:
$ 0.50

HCP7119SET2 aftermarket Mikuni carb vacuum piston spring seat screw LOCK WASHERS, 18-8 stainless steel, set of 2:
$ 0.75

HCP7119SET8 aftermarket Mikuni carb vacuum piston spring seat screw LOCK WASHERS, 18-8 stainless steel, set of 8:
$ 1.50



MIKUNI CARB FUEL SUPPLY AND BOWL OVERFLOW T-FITTINGS, CONNECTOR TUBES, AND O-RINGS:


mtz1) OEM Mikuni fuel inlet T-FITTING AND CONNECTOR SUPPLY TUBES. The swivelling plastic t-fitting is used as the intake port from the petcock and "splits" the fuel flow to the left and right sides of the carb banks, while the aluminum fuel connector pipes are used to connect the outer carbs to the center carbs for incoming fuel supply. The inlet T-fitting was plastic, and was equipped with built in anti-leak "ribs" where they enter the carb bodies, while the aluminum connector tubes use separate o-rings (listed further below) to provide a leak-proof connection into the carb bodies.

HCP5166 OEM plastic fuel inlet T-FITTING, use 1 on all XJ550 models in-between the #2 and #3 carbs.
$ 30.00

HCP9865 OEM plastic fuel inlet T-FITTING, use 1 on all XJ550 models in-between the #2 and #3 carbs.
$ 32.00




HCP5165 OEM aluminum fuel SUPPLY TUBE, use 1 each on all XJ550 models in-between the #1/2 and the #3/4 carbs. Each:
$ 22.50

HCP5239 OEM aluminum fuel SUPPLY TUBE, use 1 each on all XJ650 Turbo and all XJ700-X models in-between the #1/2 and the #3/4 carbs, and 1 on XJ900RK models between the #2/3 carbs. Each:
$ 21.95



HCP9866 OEM fuel bowl vent/overflow plastic T-FITTING, use 1 each on all XJ700-X models in-between the #1/2 and #3/4 carbs.
$ 17.95

HCP9867 OEM fuel bowl vent/overflow plastic T-FITTING, use 1 each on all XJ900RK models in-between the #1/2 and #3/4 carbs.
$ 17.95


HCP9864 OEM fuel bowl vent/overflow aluminum CONNECTOR TUBE, use 1 each on all XJ650 Turbo models in-between the #2/3 carbs. Each:
$ 19.95



mmm1) OEM and aftermarket Mikuni fuel rail connector pipe O-RING.....all fours carbs share a common fuel supply, and this fuel supply is distributed to each carb via either plastic, brass or aluminum tubes and T-fittings that connects one carb to another. These tubes fits into a machined bores in the carb base, and the tubes are sealed in their bores with these rubber o-rings. Additionally, XJ650 Turbo and XJ700-X and XJ750-X models also used bowl vent connectors (plastic T-fittings) that also used o-rings. NOTE: original seals were "D-rings" rather than "O-rings", but are now serviced only as o-rings, but are the correct shape and firmness to provide a leak-proof fit. You will only be able to access these seals if you break the carbs out of their rack! (and if you do break the rack, you need to replace these seals).

NOTE: on all Mikuni model carbs, the factory parts diagram show the use of a plastic, ribbed fuel inlet T-fitting that does NOT use any o-rings.....the molded in "ribs" are supposed to take the place of o-rings for sealing the t-fitting to the carb body. To be honest, like many of you have commented, I don't understand either how the ribs on the plastic fitting by themselves could have maintained an effective seal, but......I'm not fuel line engineer! You can always add an extra two o-rings to this t-fitting to provide a more secure connection.


- Use 4 seals per fuel connector pipe in-between carbs 1&2 and 3&4, or a total of 8 seals per entire carb rack, for Mikuni carbs used on all XJ550 models. NOTE: the plastic fuel inlet "T" fitting does not use o-rings.

- Use 4 seals per fuel connector pipe in-between carbs 1&2 and 3&4, and use 4 seals per bowl overflow connector pipes, for a total of 20 seals per entire carb rack, on the Mikuni carbs used on all XJ650 Turbo models. NOTE: the plastic fuel inlet "T" fitting does not use o-rings.

- Use 4 seals per fuel connector pipe in-between carbs 1 & 2 and in-between 3 & 4, and use 2 seals on each bowl overflow "T" connector pipes, or a total of 12 seals per entire carb rack, for Mikuni carbs used on all XJ700-X and XJ750-X models. NOTE: the plastic fuel inlet "T" fitting does not use o-rings, and the bowl overflow plastic T-connectors actually use a slightly larger o-ring. However, these o-rings will fit the bowl-overflow T-fittings, although they will result in a slightly more loose fitting pipe in the carb bores. Since these bowl overflow T-connectors don't actually carry fluid---they normally just vent fuel vapors---the slightly looser fitment is not an issue.

- In case you're wondering, XJ1100 models used two plastic T-fittings for fuel inlet supply, and those fittings do NOT use any o-rings. There are no bowl vent connector tubes on 1100's, so there are no o-rings used at all on 1100 models!


HCP3458 OEM Mikuni fuel line Tube O-RING, each:
$ 3.50

HCP3458SET8 OEM Mikuni fuel line Tube O-RINGS, set of 8:
$ 26.50

HCP3458SET12 OEM Mikuni fuel line Tube O-RINGS, set of 12:
$ 39.00

HCP3458SET20 OEM Mikuni fuel line Tube O-RINGS, set of 20:
$ 62.00



HCP6880 Aftermarket Mikuni fuel line Tube O-RING, made from a durable Buna-N rubber material, fits just like the originals at a much better price. Each:
$ 1.00

HCP6880SET8 Aftermarket Mikuni fuel line Tube O-RINGS, set of 8:
$ 7.50

HCP6880SET12 Aftermarket Mikuni fuel line Tube O-RINGS, set of 12:
$ 10.50

HCP6880SET20 Aftermarket Mikuni fuel line Tube O-RINGS, set of 20:
$ 17.00




FUEL SYSTEM HARDWARE:

A variety of different style fasteners and finishes are available, ranging from original OEM grade and finish to stainless steel, polished, or black-oxide coated fasteners. This is the easiest way to replace your missing or damaged original hardware or to upgrade the appearance or durability of your hardware! Many different styles are available for most fasteners, so please review your choices carefully.



MIKUNI CARBS HARDWARE:

MIKUNI CARB HAT HARDWARE:

NOTE: the following carb hat (technically known as a diaphram cover) SCREWS fit all XJ550, XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models. Original hat screws were panhead phillips drive alloy steel with a natural finish, and did not use any washers. Use 4 per carb, 16 per rack.


HCP60 OEM Mikuni carb "Hat" SCREW, alloy steel, natural finish, panhead phillips-drive, each:
$ 1.00

HCP60SET4 OEM Mikuni carb "Hat" SCREWS, set of 4:
$ 3.50

HCP60SET16 OEM Mikuni carb "Hat" SCREWS, set of 16:
$ 13.00



HCP910 Aftermarket Mikuni carb "Hat" SCREW, alloy steel, natural finish, panhead phillips-drive, each:
$ 1.00

HCP910SET4 Aftermarket Mikuni carb "Hat" SCREWS, set of 4:
$ 3.00

HCP910SET16 Aftermarket Mikuni carb "Hat" SCREWS, set of 16:
$ 9.00



HCP62 Aftermarket Mikuni carb "Hat" SCREW, 18-8 stainless steel panhead phillips-drive, each:
$ 1.25

HCP62SET4 Aftermarket Mikuni carb "Hat" SCREWS, set of 4:
$ 4.50

HCP62SET16 Aftermarket Mikuni carb "Hat" SCREWS, set of 16:
$ 14.00


HCP308 Aftermarket Mikuni carb "Hat" SCREW, 18-8 stainless steel, button head with a hex-drive, each:
$ 1.25

HCP308SET4 Aftermarket Mikuni carb "Hat" SCREWS, set of 4:
$ 4.50

HCP308SET16 Aftermarket Mikuni carb "Hat" SCREWS, set of 16:
$ 14.00



HCP310 Aftermarket Mikuni carb "Hat" SCREW, 18-8 stainless steel socket-head cap screw (allen head) with a hex-drive, each:
$ 1.25

HCP310SET4 Aftermarket Mikuni carb "Hat" SCREWS, set of 4:
$ 4.50

HCP310SET16 Aftermarket Mikuni carb "Hat" SCREWS, set of 16:
$ 14.00



HCP64 Aftermarket Mikuni carb "Hat" SCREW, black-oxide coated alloy steel socket head cap screw (a/ka allen head) with a hex drive, each:
$ 1.00

HCP64SET4 Aftermarket Mikuni carb "Hat" SCREWS, set of 4:
$ 3.50

HCP64SET16 Aftermarket Mikuni carb "Hat" SCREWS, set of 16:
$ 12.00



MIKUNI CARB BOWL HARDWARE:

bds2) OEM and aftermarket Mikuni carb bowl-to-body MOUNTING SCREW. All Mikuni model carbs originally used a panhead, phillips-drive bowl mounting screw that had an integral lockwasher. Current OEM and most of the replacement screws do not have the integral lockwasher, and a separate lockwasher must be ordered from the selection listed below. NOTE: original screws were plated alloy steel with a natural finish.


For XJ550 models:


HCP3696 OEM Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, phillips-drive panhead screw with natural finish. Use 4 per bowl, each:
$ 2.50

HCP3696SET4 OEM Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 9.50

HCP3696SET16 OEM Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 16:
$ 34.00



HCP5482 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, phillips-drive panhead screw with natural finish. Use 4 per bowl, each:
$ 1.00

HCP5482SET4 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 3.00

HCP5482SET16 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 16:
$ 9.00




HCP5486 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, phillips-drive panhead screw with gold chromate finish. Has an integral lockwasher. Use 4 per bowl, each:
$ 1.00

HCP5486SET4 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 3.50

HCP5486SET16 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, set of 16:
$ 13.00




HCP5483 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, socket head cap screw (allen headed hex-drive), 18-8 stainless steel with a bright polished finish. Use 4 per bowl, each:
$ 1.00

HCP5483SET4 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 3.00

HCP5483SET16 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 16:
$ 9.50




HCP5484 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, socket head cap screw (allen headed hex-drive), black-oxide coated steel finish. Use 4 per bowl, each:
$ 1.00

HCP5484SET4 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 3.00

HCP5484SET16 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 16:
$ 9.50




HCP5485 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREW, button head cap screw (rounded head hex-drive), 18-8 stainless steel with a bright polished finish. Use 4 per bowl, each:
$ 1.50

HCP5485SET4 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 4:
$ 3.50

HCP5485SET16 Aftermarket Mikuni BS28 series carb bowl-to-body MOUNTING SCREWS, set of 16:
$ 12.50



For XJ650 Turbo, XJ700-X, XJ750-X, XJ900RK, and XJ1100 models:


HCP2940 OEM Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body MOUNTING SCREW. Note: these screws now have a dark gray coated finish, and are approximately 2mm longer than stock, panhead phillips drive. Use 4 per bowl, each:
$ 1.50

HCP2940SET4 OEM Mikuni carb bowl-to-body black oxide MOUNTING SCREWS, set of 4:
$ 5.00

HCP2940SET16 OEM Mikuni carb bowl-to-body black oxide MOUNTING SCREWS, set of 16:
$ 18.00




HCP2643 aftermarket Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body MOUNTING SCREW, zinc-plated alloy steel, natural finish, approximately 2mm longer than stock, panhead phillips drive. Use 4 per bowl, each:
$ 0.75

HCP2643SET4 aftermarket Mikuni carb bowl-to-body natural finish MOUNTING SCREWS, set of 4:
$ 2.50

HCP2643SET16 aftermarket Mikuni carb bowl-to-body natural MOUNTING SCREWS, set of 16:
$ 9.00





HCP1358 aftermarket Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body gold chromate MOUNTING SCREW, with an integral lock washer as original, panhead phillips drive. Use 4 per bowl, each:
$ 1.00

HCP1358SET4 aftermarket Mikuni carb bowl-to-body gold chromate MOUNTING SCREWS with lock washers, set of 4:
$ 3.50

HCP1358SET16 aftermarket Mikuni carb bowl-to-body gold chromate MOUNTING SCREWS with lock washers, set of 16:
$ 13.00




HCP302 aftermarket Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body 18-8 stainless steel MOUNTING SCREW, panhead phillips-drive, approximately 2mm longer than stock. Use 4 per bowl, each:
$ 1.00

HCP302SET4 aftermarket Mikuni carb bowl-to-body 18-8 stainless steel MOUNTING SCREWS, phillips head, set of 4:
$ 3.50

HCP302SET16 aftermarket Mikuni carb bowl-to-body 18-8 stainless steel MOUNTING SCREWS, phillips head, set of 16:
$ 12.00




HCP303 aftermarket Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body MOUNTING SCREW, button head cap screw (rounded head hex-drive), 18-8 stainless steel with a bright polished finish, approximately 2mm longer than stock. Use 4 per bowl, each:
$ 1.50

HCP303SET4 aftermarket Mikuni carb bowl-to-body stainless button-head MOUNTING SCREWS, set of 4:
$ 5.00

HCP303SET16 Replacement Mikuni carb bowl-to-body stainless button-head MOUNTING SCREWS, set of 16:
$ 16.00




HCP56 aftermarket Mikuni BS30, BS33, BS34, and BS35 carb bowl-to-body MOUNTING SCREW, allen head hex-drive, 18-8 stainless steel with a bright polished finish, approximately 2mm longer than stock. Use 4 per bowl, each:
$ 1.50

HCP56SET4 aftermarket Mikuni carb bowl-to-body stainless MOUNTING SCREWS, set of 4:
$ 4.50

HCP56SET16 aftermarket Mikuni carb bowl-to-body stainless MOUNTING SCREWS, set of 16:
$ 15.00




HCP58 afterma

 

Woah. OK, so i just began tearing into my carbs (repair manual in hand) and it looks like i have my work cut out for me. After sitting for several years I have a lot of stuck screws. Many of which are going to be mangled beyond recognition. I will have to get it all apart and then make a list of replacement parts. Looks like I'm not going to get off easy though.
Thanks a bunch for the list Chacal. I will definitely be in touch.

 

Hey Dawg, just give me a holler when you're ready. And trust me, doing a complete and thorough job is actually the true meaning of "getting off easy"!

 

chacal,
i have a xj650 turbo that i got on a trade for work done . anyways carbs have been sitting in parts cleaner for the better of 2 years as the previous owner was a retard .. lot of corrosion everything froze. looks like junk to me . do you guys know where i can find replacement carbs or good set to rebuild ? do you think the carbs i have are worth fooling with?

 

Hey Iron, I think you'll find that any set of carbs that have been setting around for a bit are going to be as your described. The 650 Turbo carbs are unique to that model, so they're kinda hard to find. Luckily, most of the replacable items ARE available, so it really comes down to complete dis-assembly and thorough cleaning of every last part......time consuming but not rocket science. You can even soda-blast the bodies to clean up the aluminum corrosion and make those bright and shiny-new looking. Other than that, the rest of it is straight rebuild parts and procedures.......

 

chacal
is there a general rebuild kit for the xj650 carb or do i have buy every thing individually?

 

Hey Iron, unfortunately, for the Turbo carbs there is no pre-assembled rebuild kit...........

 

Now I see the reason for all the carb posts! There goes my budget!! lol

 

Iron,
Check out A&J Cycle Salvage out of philadelphia. If you can't find a set of those carbs on eBay then A&J would be your next best bet. Just google them and go to thier site and email them what you need. Hope this was helpful.

 

There are a couple of 650 Turbos parted out on eBay right now...

 

@chacal Are these parts still available, as I see the list is posted 12 years ago?

 

Yes, they are. Start a conversation with him and he'll get you the right parts quickly and at a fair price.