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Hilly's 1999 XL1200S

Hilly's 1999 XL1200S

Hilly
6 days ago

I got back to the carby this arvo, won't go into too much detail but a couple of little tricks if you are reusing the diaphragms.
With the accelerator pump and slide diaphragms smear a real light bead of dialectic grease around the outer sealing edges, helps them stay in the groves and as you put the covers on you can twist them real gentle like as you push down to seat the lips into the grooves, works a treat.
An extra for the slide diaphragm is hold the slide up with ya thumb so the diaphragm is cupped downwards, this helps keep the sealing edge where it's supposed to be as you push the cover down, old diaphragms tend to want to pop out of the groove if the slide is bottomed out.

Exhibit A

Exhibit B

Hilly
6 days ago

A bit more to the story, got all back together, went to take a pic of the grease and #2 JIS Screwdriver that works a bloody treat on JIS screw heads! Go figure! See anything wrong in this pic?

JIS Screwdriver, highly recommend and cat grease

Float bowl on no accelerator rod! Edited, wrong pic before

Hilly
6 days ago

So, having proven I shouldn't be unsupervised I rectified my negligence, first CV carby I've gone through in over 20 years I reckon, I don't have a method of laying out parts, I chuck em all in the cleaner and enjoy the challenge lol.

A very clean slide, I set the idle mixture screw to 3 turns out, will adjust that after its running again.

All back together with a new choke cable, set the idle screw to just moving the butterfly, will adjust that as well when it's going.

Checking the little washer thicknesses for if I need to shim the needle later on

Hilly
5 days ago

Pulled the intake manifold off as I'm going to be changing it anyway, had a look in the intake ports with an LED torch and my heart sank a little, puddles of oil.
As I sat there contemplating what my next move should be it occurred to me the "oil" I could see looked like fresh diff oil mmmmm
I dipped a scribe in liquid and it came out "clean", so I rolled up a tissue and dipped the ends in each port, it wicked up the tissue paper really quickly, a quick smell and it's fuel lol.
The valves don't look as bad in person as they do in the pics, the LED light makes it look like there is crud everywhere, there is a bit of carbon because of the internal breathers and questionable tuning but it'll run ok.

Front

Rear

speedzter
5 days ago

Quoting Hilly on 15 Nov 2025 10:14 AMedited: 15 Nov 2025 10:52 PM
A bit more to the story, got all back together, went to take a pic of the grease and #2 JIS Screwdriver that works a bloody treat on JIS screw heads! Go figure! See anything wrong in this pic?

JIS Screwdriver, highly recommend and cat grease

Float bowl on no accelerator rod! Edited, wrong pic before

You'll need to tell us whats wrong !!

Hilly
5 days ago

Quoting Hilly on 15 Nov 2025 10:14 AMedited: 15 Nov 2025 10:52 PM
A bit more to the story, got all back together, went to take a pic of the grease and #2 JIS Screwdriver that works a bloody treat on JIS screw heads! Go figure! See anything wrong in this pic?

JIS Screwdriver, highly recommend and cat grease

Float bowl on no accelerator rod! Edited, wrong pic before

Quoting speedzter on 16 Nov 2025 01:46 AM
You'll need to tell us whats wrong !!

I thought I did, I put the fuel bowl on and left the accelerator pump rod out, not major, just humbling 😁

Hilly
5 days ago

Today was get as much rust off the cheap Taiwanese forward controls as I could and fit them up day, they came as a jumble of rusty parts in a box, pretty rough looking.
I cleaned them up as best I could, sorted them into two piles and started putting them on, the left hand side wasn't too difficult to work out but the right was a challenge.
There were bits missing, bits that didn't belong, bits that could fit more than one way and looked fine on until they didn't, I think I pulled the drive pulley cover off 3 or 4 times trying different spacers and orientations.
There was no brake lever pad but I had an old Kuryakyn one in a box with some old brake lines, the fumes had dissolved the glue and the pads had fallen off but beggars can't be choosers.
It didn't fit the arm so I took to it with the Dremel to make it fit and glued the rubbers back on, anyway got it sorted in the end.

Most off the right side bits

Left side as good as I can get it

Right side cleaned up

Right on

Left on

The pad doesn't look too bad.....kinda

Stuart and obisteve like this post

Hilly
19 hours ago

Is 80 grit a rough enough finish on a carby bike intake manifold?

speedzter
15 hours ago

Is that what the hillbillies call hand ported ??
Are you using a Tootsie roll ? (cartridge)

Hilly
13 hours ago

Haha, threw it down on the table and had at it.
I used the die grinder with a stone to start with, didn't trust myself with a burr, then a flapper wheel, then 120 grit paper to get a feel of the shape, then little files and 80 grit paper to get the bits that needed getting.
I'll post a pic later, dunno if I'm 100% finished yet, OCD has kicked in, I wouldn't have bothered with it at all if it had looked as good as the one I took off but it was ugly in there man, it needed lovin' 😁

obisteve likes this post

Hilly
7 hours ago

Old one and new one, don't have any pics of the new one before clean up, haven't hogged it out, just cleaned it up, if you look real close you can still see the remnants of the internal cast seams, they were bloody horrible I kid you not, if you look at the carby spigot on the new one it is wider at the seam points than than the old one, that is how it was when I got it, I didn't make it any worse in that regard, as I said earlier if the new one had looked like old I wouldn't have touched it.

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