New to XS member, project bike excited to wrench

Thanks Chris, that is understood . Just posting as reference and observational. It Surprised a newbie like me even tho you had previously warned this when I came across the exploded 79 carb diagram. I'm just teaching an old dog new tricks ;)

My Float needles:
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Having trouble removing bloody float needle valve. It had a screw and crescent ring holding outside flange, but with that removed it still doesn't want to come out... Circular so nothing good to grab onto. Tried light pliers but no success and worried I'll tear it up...

Suggestions?

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The o-ring is stuck as it tends to be. Use a little oil around it and then grab the lip with a set of small wire cutters then twist. With as old as the valve looks I would just replace the entire thing.
 
What o ring???
:laugh: so covered in crap I couldn't see it haha
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Thanks for suggestions! Oil overnight with locking pliers did the trick
 

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Theres a set of XS360 carbs in the classifieds. Theyre better for the 400s. I use my 360 carbs on the 400.

I know it takes away from the fun of rebuilding, but I think it the end it will cost less.
 
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Little discouraging I found these 2 washers after having removed what I thought were all main components and began spraying carb cleaner and air. Both fell out separately when carb body was on my cloth and I can't say I had any idea where they fell from... any thoughts, don't see them in the diagram. Pilot included for size reference only:
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Thanks Chris!! My 1980 400G didn't have a rubber or brass plug sitting on the pilot jet... I'm guessing that isn't unrelated to the fact it wouldn't run properly. From what I gather from the parts diagrams, it should have the plug sitting over the pilot jet.

Anybody have dimensions of the rubber plug? EDIT: Just realized I can measure ID with my gauge, will update accordingly. Reasoning: rubber plugs are expensive with shipping from certain sources!

Update for thread integrity if anyone looking for pilot jet plug opening per my measurement: 5.45mm inner diameter. 9.57mm outer diameter
 
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xschris said:
https://www.ebay.com/itm/Carb-plugs-4-pack-Yamaha-XS650-XS1100/191790293421?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m1438.l2649 Plugs.
Click to expand...

Ordered! In my experience manufacturers generally don't place parts in places because they run better without them... even with environmental regs. Mine had them removed :rolleyes:

Any thoughts as to what these washers came off? I don't see them in the parts diagram for my model year. I know the mixture screws in earlier models had an extra washer... but not that I could tell in the 1980 SOHCs...
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You need those plugs or the bike will run poorly. 80-82 sohc xs400 had caps over the pilot mix screws and where preset from the factory. You need to remove the caps to access them. There are threads on this. The 80-84 xs650 also had this. Looking at that model bike might yield more results. The pic is what they look like and how they are assembled. With a stock bike 2-3 turns out from lightly seated is a good starting point. I am not sure where those washers go but if your bike was missing the pilot jet plugs who knows what the p.o. was doing with it.
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I ditch those valve filters. Use an in-line one between the petcock and carbs and those are un-needed. It's easier to replace an in-line than remove carbs to get to those nets.
 
xschris said:
I ditch those valve filters. Use an in-line one between the petcock and carbs and those are un-needed. It's easier to replace an in-line than remove carbs to get to those nets.
Click to expand...

I installed an in line filter too....tank interior had quit a bit of surface rust so bike needs as many filter barriers as I can get before the carbs.
Tank cleaned up pretty good but still has collected a bit of "finite" material in the fuel filter.
Using one of those "epoxy" fuel tank liner kits is my last resort.
I've seen some of those fail miserably and are a big mess when that happens.
.
 
Finally got A few hours to dedicate to it with a mate. I cleaned thru passageways a second time and reassembled carbs, now with pilot rubber plugs. Installed new fuel filter and replaced all fuel lines, installed new carb boots. Petcock I bought didn't fit so refastened original for time being to test.

Installed my new float valves seemed to be a good fit and then float needle sits somewhat loose in the opening. Brass floats set to 26mm from gasket seat (no gasket when measuring).

Set to prime to fill bowls and tried to start it up without luck. Gas started flowing at modest rate out of the left air filter (lower on side stand) and even a bit began to leak from where my new boots met the engine.

I now plan to: rubber mallet moderate knock to see if it free floats, otherwise disassemble and inspect valve seat (again) and verify no holes in floats by submerging in hot water. 1 Diaphragm has some spots that look poor/dried out that are concerning but shouldn't be causing free gas flow into filter/engine. I'll inspect anyway with filters off.
I'll also use goo-gone on boot seat where there was a leak to better prepare gasket seat and then use high temp RTV gasket sealant as well (on both sides of gasket I presume).
 
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