Carb slide = 27mm OD (as best as I can measure) label says 2.5 Needle says 4E1 Main jet appears to be a 140 Pilot jet is a 40 I have the following pilot jet sizes: 30, 40, 45 & 50 I don't have additional main jets. I can't ID the needle orifice. No markings on it. Appears to possibly been scratc...

OK. I will pull the carb apart again. I will check the pilot jet with a magnifier and get all the info you asked for. Should take me about an hour. It's currently 10 am MSDT locally. I really do appreciate your making this effort with me. If I seemed like I was going off half cocked or some other pe...

OK Ed. I went through the carb again today. There's no identifying marks on the pilot jet. The main jet is a 140 or at least that is what it looks like from pulling it out. I'm still having an intermittent issue. When I go out to the bike cold, it seems to want to start. But as soon as it warms up, ...

Well, I have no idea what the stock settings are. Seems at this point I have a 24mm carb, at least that's what I've been told. I have the air screw out 1.75 turns from all the way in. I have the idle screw at 2.5 turns out from all the way in, and the needle has the circlip at 3. I don't know where ...

So Ed. Do I understand you to mean that you measure from the Inside cover? The one that covers the shifter mechanism? I managed to adjust it some. Now getting gears 1,2 & 3 but it is a bit hard to shift. Rode it around the block and it started rainin. So I will adjust it more tomorrow. I should ...

Ed. When I opened the cover earlier, the shifter arm was striking the inside of the magneto cover and the sliding pin was pushing it's way out into the space covered by the small cover! Reading the manual, it says Measurement Method Measure the inside face of the sliding pin. It should be 35.1mm fro...

Ed. The top of the last page, page 64, is cut off on top and I can't read the beginning of this page on tuning the carb. Any chance you could scan it and email it to me?

Also you said it would limit the top end. Can you recommend what additional carb I might try? ; D Victor

OK new issue. I can get her to start. At first the shifter linkage wouldn't shift from first gear to any higher gear. I pulled the left stator coverage adjusted and made sure there was nothing in the way preventing the shifter ratchet from moving. Put her back together and watched the shifting linka...

She RUNS!!! Turns out I had the blue & black wires to the coil reversed! Put a new plug in her too. Man she sounds great! Gonna put the tank on her & take a little ride around the subdivision & see what adjustments she needs! THANK YOU TO EVERYONE!!! ; D Victor!

Dan. One side of the flange says ISO & the other side says 248 with an A1 underneath the 248. The intake manifold had a 94 on it but the cylinder uses a Model 95 exhaust gasket & manifold. ; D Victor

She ran with the new paint! I Was out fishing today, so I'll get back to it tomorrow. More to come! ; D Victor

Flange? Right side? Maybe you can post a pick too? Especially since you have it off the bike! Thx! ; D Victor

Dan. Here are pics of the carb from either side. Took with my iPhone so not the best for close up.

Damned pics are upside down again on the post until you click on them for a larger view, then they appear right side up. Does anyone know why this happens with iPhone photos?!?!?!

Were your cases painted black, or are they aluminum color and it's clear coat that is flaking off? You can go to a Paint or Big Box store and get some paint stripper in a spray can. I used it on my gas tank. Spray it on, let it loosen the paint/clear coat, and scrape it off. Pretty simple. Then you ...

OK I need some help. She started before I worked on her. Now she won't start. I cleaned the carb slide and the throat of the carb so the slide would move freely again. Since she started before I did the top end work, shouldn't she start now? Ed! Can you give me some basic screw turn guidance? Idle s...

Oh and who ever wanted my old model 97 kickstart lever with the stripped splines is welcome to it now! Email me your address at viclioce@yahoo.com and I will send it to you. Also, I have the other kickstart lever which I pictured earlier in this thread. It's a good kickstart with a brand new rubber ...

Well. SUCCESS!!! I did what Tom said about grinding down the recess in the shaft to allow the bolt to pass through and screw into the other side of the shaft. I used a small rat tail rounded file and worked slowly so as not to grind away any more than I needed. The bolt went on & tightened down!...

If it's a seam you may be able to fill it with solder. But you need to make sure you wash the tank out with soap & water and then fill the tank with water, put the cap on and flip it over. Use a small butane pencil torch. Heat the area, clean it with a small wire brush and then heat it again and...

That would be the forums fault not mine! It doesn't show rubber up to me! ; D Victor

Thanks guys! It been a lot of work but I've enjoyed most of it! Now if I can just get this kickstart lever issue resolved and I can ride it! ; D Victor

AZ Shorty. The lever won't go on the shaft with the bolt in place. It doesn't clear the forward splines. The previous one was the same way and I'm sure this issue is why he stripped both the bolt and the splines inside the kickstart. I just need to be able to see inside the bolt hole, which I can no...

Had the same issue with the seals on the control shart. They were non-existent. Needed new print on control shaft and on the kickshaft. Had the tranny apart to replace all the seals anyway. The oil leaked around the control shaft while the bike was on the kickstand. I would loose about 10 ounces of ...

Ed. It will probably just be easier to drain and pull at this point. The lower frame causes some interference with tightening the bolt when the motor is in the frame and even when I move the lever down to see the hole for the bolt, I can't see inside the hole! Another thing making it difficult is th...

Paul. Please don't worry about the bolt. I can get one locally in a pack of 3 for less than it will cost you to ship a bolt to me! I appreciate the effort on your part, but it was my fault to begin with so I don't want you worrying about it! Hopefully, I ill have it all done today! ; D Victor

Well, your point is a given. My question is, HOW? It's not easily seen, can't do it by feel and it keeps screwing up the bolts. You've kind of overstated the obvious here. I'm looking for a way to actually succeed at the task. Is it done visually through the hole? If so, do I need to remove the engi...