Post by iffy on Sept 12, 2013 9:29:01 GMT
I cant remember where I found this. But it is originally written for some sort of KTM (hence the LC4 and other KTM sort of names n numbers dotted through this) but as this is the same (well, quite similar) carb used in alot of the GSXR 1100's I thought it useful to the likes of you and me.
Its on my PC as a PDF file, so I've cut n pasted it into here as well as I can. I left the names and details of the original writer in. The email address about the donations is in no way connected to me. If the admins/mods feel its appropriate to remove that, please do.
### NOTE ###: I just thought I should add this note, with regards to terminology in this the guide. There are references to the "needle jet", it is just another name for the emulsion tube. Its probably not worth mentioning to most people, but confusion does arise at times because of different names for the same thing.
Also, there is a section at the end about modifications. Please remember that this is written with KTMs in mind, not GSXRs so take it into account before you go and cut/drill or wotever you might be thinking of doing.
Anyway, I hope you find this useful
The BST-40 Bible
Written by Laramie LC4
This .pdf has been compiled and edited by dorkpunch. Please feel free to use and distribute this! My goal is to eventually have enough threads edited and formatted to make an actual service and repair manual for the LC4. If you would like to help, donations can be sent by paypal to:
smallenginecutaways@yahoo.com.
Before we begin:
1. If your carb is not out of your bike yet, don’t go any farther until it is. If you don’t know how to do that, refer to the carb removal section.
2. Once again, if you are scared to do this after reading and studying all the info available PLEASE STOP NOW!!! I don’t not want to be responsible for your carb because you rushed, didn't listen, didn't fully understand something, or didn't bother to ask a question. The process is pretty easy to follow. If you got the carb out of the bike, we should be fine.
3. You need a clean, dirt free, environment to perform this job. It is also a good idea to have good ventilation to remove fumes. You will be using cleaning agents on the carb. OK, here we go!!!
BST-40 Cleaning
Tool List
- #4 Allen Head
- larger flat head screwdriver
- long thin flat head screwdriver
- cleaning towel
- Q-tips
- carburetor cleaner
1. Remove the top of the carb. This will grant you access to the slide and needle. The carb comes stock with some phillips head screws. I highly recommend that you replace these with a higher grade, allen head. The screws can and will strip out. Don’t worry if they do or already have though, grab them with a pair of vice grips and out they come.
In figure 1 you can see I have already replaced these with the allen heads. Either way, remove these 2 bolts.
Figure 1
Once those 2 bolts are out, carefully lift up on the top of the carb. Be careful not to let the spring get away from ya. See figure 2.
2. Remove the cap and spring from the carb. You will now be able to see the diaphragm on top of the slide. This is the reason they call this carb a "CV" (constant velocity) carb. This carb lifts its slide by a vacuum. it is not directly connected to the throttle. (if you look down into the slide, you will see the top of the needle
Figure 2
and the 2 holes that are used to transfer the high/low pressure back and forth. This is what lifts the slide. One of the mods done later in this post involves increasing the size of these 2 holes to allow the transfer to happen quicker, thereby increasing throttle response. It is often referred to as "drilling the slide".)
3. Pull up on the diaphragm to remove the slide from the carb (figure 3).
4. Once the slide is removed, remove the needle by turning the slide to an angle (figure 4). Make sure to set the needle in a safe place. I usually have a plastic case or baggie that I put all of the small pieces of my carb into. this way, nothing gets lost. Now you should have something that looks like figure 5 sitting in your work area.
Figure 3
Figure 4
Figure 5
Now that you have the top end off the carb, there are a few things to inspect.
1-Inspect the top of carb. Chances are if you have never pulled your carb, or do lots of off-road riding, the top of your carb is full of dirt! Don’t freak out, this happens. It is also the major reason you need to be cleaning your carb often. As usual though, our Buddy Creeper has already solved this problem. I would HIGHLY RECOMMEND that everyone reads Creepers BST 40 Carb Venting and follow his instructions. If you do you will eliminate many of the issues that this carb can develop over time. This is what my carb looked like. I clean it every oil change and ride in extremely dusty conditions. If yours looks worse than figure 6, you need to clean it way more often.
Figure 6
2- Check that your cap-sealing surface is flat (there have been some people who have found that their cap became warped due to the stupid 2 bolt design. This allowed even more dirt to enter the carb and started causing problems). To check if it is flat, find any level straight surface (small piece of glass is the best) and check. You can also use a straight edge to check for flatness as well (figure 7). If you find your cap is warped, sorry but ya gotta buy a new one.
Figure 7
3- Check the diaphragm and slide for any wear or damage. Unroll the diaphragm and look at the inside and out, check the seal edge for tears, cracks, or anything else that doesn't look good. Check the face of the slide for wear and gouging. Once again, as a result of venting to atmosphere without filters, the slide takes a beating from the dirt that gets into the top of the carb. A small amount of wear is to be expected, but serious gouges or slots in the slide are a sign of wear and you need to replace the slide.
4- Check the needle for wear. Believe it or not, these needles have been known, due to vibration, to wear themselves to the point of breaking. When this happens the needle falls into the needle jet and plugs all the fuel flow. This basically disables your bike, so make sure you check. Sorry for the bad picture (figure 8) but once you see the second one of a damaged needle (figure 9) you will understand.
Now we move onto the bottom of the carb and removal of the float bowl. This is where we really get to the heart of the carb and gain access to the jets and the float. The first thing you need to do is remove the 2 allen head screws as shown in figure 10.
Figure 8
Figure 9
Figure 10
Once those 2 bolts are removed you can lift up on the float bowl and expose the floats and main jet (figure 11).
Figure 11
Set the float bowl aside and take a look inside the carb. You should be able to see just about everything now.
Take the time to locate the float weight (figure 12) before proceeding to the next step.
Figure 12
To remove the floats, pinch with your fingers and pull up. BE EXTREMELY CAREFUL NOT TO LOOSE THE FLOAT WEIGHT (figure 13)!
Lift the float up and out of the carb (figure 14).
Once the float is removed, inspect it for integrity, check the o-ring for wear, and place the weight someplace safe (figure 15).
Figure 13
Figure 14
Figure 15
Now with the float out of the carb you should be able to locate all of the major components inside of the float bowl.
Take the time and find; the main jet, idle jet, fuel/air screw, the needle valve, and idle screw (figure 16).
Figure 16
Right, I'm going to make myself some dinner, I'll finish this off inna bit
Its on my PC as a PDF file, so I've cut n pasted it into here as well as I can. I left the names and details of the original writer in. The email address about the donations is in no way connected to me. If the admins/mods feel its appropriate to remove that, please do.
### NOTE ###: I just thought I should add this note, with regards to terminology in this the guide. There are references to the "needle jet", it is just another name for the emulsion tube. Its probably not worth mentioning to most people, but confusion does arise at times because of different names for the same thing.
Also, there is a section at the end about modifications. Please remember that this is written with KTMs in mind, not GSXRs so take it into account before you go and cut/drill or wotever you might be thinking of doing.
Anyway, I hope you find this useful
The BST-40 Bible
Written by Laramie LC4
This .pdf has been compiled and edited by dorkpunch. Please feel free to use and distribute this! My goal is to eventually have enough threads edited and formatted to make an actual service and repair manual for the LC4. If you would like to help, donations can be sent by paypal to:
smallenginecutaways@yahoo.com.
Before we begin:
1. If your carb is not out of your bike yet, don’t go any farther until it is. If you don’t know how to do that, refer to the carb removal section.
2. Once again, if you are scared to do this after reading and studying all the info available PLEASE STOP NOW!!! I don’t not want to be responsible for your carb because you rushed, didn't listen, didn't fully understand something, or didn't bother to ask a question. The process is pretty easy to follow. If you got the carb out of the bike, we should be fine.
3. You need a clean, dirt free, environment to perform this job. It is also a good idea to have good ventilation to remove fumes. You will be using cleaning agents on the carb. OK, here we go!!!
BST-40 Cleaning
Tool List
- #4 Allen Head
- larger flat head screwdriver
- long thin flat head screwdriver
- cleaning towel
- Q-tips
- carburetor cleaner
1. Remove the top of the carb. This will grant you access to the slide and needle. The carb comes stock with some phillips head screws. I highly recommend that you replace these with a higher grade, allen head. The screws can and will strip out. Don’t worry if they do or already have though, grab them with a pair of vice grips and out they come.
In figure 1 you can see I have already replaced these with the allen heads. Either way, remove these 2 bolts.
Figure 1
Once those 2 bolts are out, carefully lift up on the top of the carb. Be careful not to let the spring get away from ya. See figure 2.
2. Remove the cap and spring from the carb. You will now be able to see the diaphragm on top of the slide. This is the reason they call this carb a "CV" (constant velocity) carb. This carb lifts its slide by a vacuum. it is not directly connected to the throttle. (if you look down into the slide, you will see the top of the needle
Figure 2
and the 2 holes that are used to transfer the high/low pressure back and forth. This is what lifts the slide. One of the mods done later in this post involves increasing the size of these 2 holes to allow the transfer to happen quicker, thereby increasing throttle response. It is often referred to as "drilling the slide".)
3. Pull up on the diaphragm to remove the slide from the carb (figure 3).
4. Once the slide is removed, remove the needle by turning the slide to an angle (figure 4). Make sure to set the needle in a safe place. I usually have a plastic case or baggie that I put all of the small pieces of my carb into. this way, nothing gets lost. Now you should have something that looks like figure 5 sitting in your work area.
Figure 3
Figure 4
Figure 5
Now that you have the top end off the carb, there are a few things to inspect.
1-Inspect the top of carb. Chances are if you have never pulled your carb, or do lots of off-road riding, the top of your carb is full of dirt! Don’t freak out, this happens. It is also the major reason you need to be cleaning your carb often. As usual though, our Buddy Creeper has already solved this problem. I would HIGHLY RECOMMEND that everyone reads Creepers BST 40 Carb Venting and follow his instructions. If you do you will eliminate many of the issues that this carb can develop over time. This is what my carb looked like. I clean it every oil change and ride in extremely dusty conditions. If yours looks worse than figure 6, you need to clean it way more often.
Figure 6
2- Check that your cap-sealing surface is flat (there have been some people who have found that their cap became warped due to the stupid 2 bolt design. This allowed even more dirt to enter the carb and started causing problems). To check if it is flat, find any level straight surface (small piece of glass is the best) and check. You can also use a straight edge to check for flatness as well (figure 7). If you find your cap is warped, sorry but ya gotta buy a new one.
Figure 7
3- Check the diaphragm and slide for any wear or damage. Unroll the diaphragm and look at the inside and out, check the seal edge for tears, cracks, or anything else that doesn't look good. Check the face of the slide for wear and gouging. Once again, as a result of venting to atmosphere without filters, the slide takes a beating from the dirt that gets into the top of the carb. A small amount of wear is to be expected, but serious gouges or slots in the slide are a sign of wear and you need to replace the slide.
4- Check the needle for wear. Believe it or not, these needles have been known, due to vibration, to wear themselves to the point of breaking. When this happens the needle falls into the needle jet and plugs all the fuel flow. This basically disables your bike, so make sure you check. Sorry for the bad picture (figure 8) but once you see the second one of a damaged needle (figure 9) you will understand.
Now we move onto the bottom of the carb and removal of the float bowl. This is where we really get to the heart of the carb and gain access to the jets and the float. The first thing you need to do is remove the 2 allen head screws as shown in figure 10.
Figure 8
Figure 9
Figure 10
Once those 2 bolts are removed you can lift up on the float bowl and expose the floats and main jet (figure 11).
Figure 11
Set the float bowl aside and take a look inside the carb. You should be able to see just about everything now.
Take the time to locate the float weight (figure 12) before proceeding to the next step.
Figure 12
To remove the floats, pinch with your fingers and pull up. BE EXTREMELY CAREFUL NOT TO LOOSE THE FLOAT WEIGHT (figure 13)!
Lift the float up and out of the carb (figure 14).
Once the float is removed, inspect it for integrity, check the o-ring for wear, and place the weight someplace safe (figure 15).
Figure 13
Figure 14
Figure 15
Now with the float out of the carb you should be able to locate all of the major components inside of the float bowl.
Take the time and find; the main jet, idle jet, fuel/air screw, the needle valve, and idle screw (figure 16).
Figure 16
Right, I'm going to make myself some dinner, I'll finish this off inna bit