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Old 01-05-2013, 08:40 PM   #1 (permalink)
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81 yamaha exciter 440 carb

Hello! Hope all you guys have been out riding sled! I was just wondering on specifics for cleaning the carbs on this. its the Keihin carb. The reason I ask is my sled wont start by pulling on it, I have to dump gas down the cylinder to get it to go. Once it is running it stays running and starts up first pull when warm. I would like to get it so I can pull it 1-3 times for it to run. any help would be awesome!!
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Old 01-05-2013, 09:01 PM   #2 (permalink)
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that carb is simplistic by design. with the age though you may encounter some problems so dont animal the jets, be gentle and patient. clean the outside thoroughly before heading in.

only a few circuits to address: main jet, pilot jet, air screw, and the choke plunger. factor in the needle and seat just for fun. there is also a passage on the airbox side that you need to be sure is clean as well.

if you have the carb out, remove the float bowl. the screws securing this strip easily so be prepared. one you have the bowl off, you can remove the main jet and give it a once over then place it in the bowl.

next you will want to remove the pilot jet. you need a small regular screwdriver that fits well. i would highly recommend some patience and some pb blast or equivalent prior to your removal attempt. let it soak! the heads of these strip very effortlessly and then your effed.

after you have this removed, toss it in the bowl. form here you want to remove the air mixture screw. turn it in counting the exact number of turns down to 1/8, then log this number and back it all the way out.

unbolt the choke plunger and keep your eye on the spring and the plunger attached to the end of the cable(they like to fly). account for all associated parts.

you can remove the float if you want, more on that if needed.

now fill the float bowl with both jets along with the air screw with carb cleaner and let it soak.

take some spray cleaner or compressed air and blow through all the circuits you have just opened up. if it goes in, it has to come out somewhere. if not, work at it till it does.

inspect the jets. you should be able to see unobstructed light through them. if not, run a wire, air, or whatever until they are clean and clear.

reassemble, reset the air screw, and you should be good to go. sometimes hard starting like you described can be associated with the choke plunger or its adjustment.
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Old 01-06-2013, 11:52 AM   #3 (permalink)
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Here are some basic specs for sea level:

Throttle Cable Free Play: 0.5 - 1.0mm (0.02 - 0.04 in)

Idle: 1500 rpm

Oil Pump Free Play: 25mm +- 1mm (0.98 in +- 0.04 in)

(measure this by pulling the cable sleeve out of the carb, and measuring at the seat and the tip of the sleeve)

Slow Adjuster: 1 5/8 turns out from lightly seated

Main Jet: #145
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1997 Yamaha Vmax XTC ER 600 7770 MI
1979 Yamaha Exciter 440 6231 MI
1997 Yamaha GP 1200 Triple 118.9 hrs.
1967 Mercury Cougar XR7 87,000 MI
2014 Season Mileage:1466
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Old 01-06-2013, 11:55 AM   #4 (permalink)
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thanks for the input!! how should I set the plunger on this. I dropped it taking the carb out and cant get it out, so I just ordered a new one, do I screw everything down tight on it?
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Old 01-06-2013, 12:05 PM   #5 (permalink)
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I'd leave the adjustment on the cable the same that it was, if your just replacing the plunger.
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WAKE-UP AND SMELL THE TWO STROKE

Toys:
1997 Yamaha Vmax XTC ER 600 7770 MI
1979 Yamaha Exciter 440 6231 MI
1997 Yamaha GP 1200 Triple 118.9 hrs.
1967 Mercury Cougar XR7 87,000 MI
2014 Season Mileage:1466
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Old 01-06-2013, 01:12 PM   #6 (permalink)
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Quote:
Originally Posted by Yamaha440 View Post
I'd leave the adjustment on the cable the same that it was, if your just replacing the plunger.
whats the cable freeplay supposed to be on that model? i would adjust it simply due to the possibility of cable stretch or being misadjusted originally.
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Old 01-06-2013, 01:46 PM   #7 (permalink)
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I have never been able to locate it though any of my manuals. In fact, it has nothing on adjusting the choke.
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WAKE-UP AND SMELL THE TWO STROKE

Toys:
1997 Yamaha Vmax XTC ER 600 7770 MI
1979 Yamaha Exciter 440 6231 MI
1997 Yamaha GP 1200 Triple 118.9 hrs.
1967 Mercury Cougar XR7 87,000 MI
2014 Season Mileage:1466
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Old 01-06-2013, 03:19 PM   #8 (permalink)
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got my carb all cleaned up, put it on and after about 5 or so pulls she took off..........will go out later and pull to make sure, had a lot of crap come out one of the holes in the bowl. now i just have to wait for my new plunger and I will be golden. Thanks for the help! you guys are awesome!!
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Old 01-07-2013, 06:59 PM   #9 (permalink)
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when your new plunger comes in, set your choke cable to have a gap between the cable end and the adjuster end between 1.5 and 2.5mm.
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Old 01-28-2013, 10:44 PM   #10 (permalink)
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awesome write up yamahadad!!!
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