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DB2 Junior refresh
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Tue Jul 07, 2020 7:17 am    Post subject: Reply with quote

And, just because 2bims seems to like ‘shiney’ stuff Wink







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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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2bims



Joined: 03 Apr 2010
Posts: 7289

PostPosted: Tue Jul 07, 2020 8:55 am    Post subject: Reply with quote

Looking lovely Brian....although I was dissappointed that there are only 3 pictures....and as such you now suffer the punishment of me pointing out that you cheated...and only cleaned up the front face of the rear disc...shame on you.....and.....theres a couple of black marks on the alloy rear brake caliper hanger/spacer that should buff up and out with some metal polish......now get busy....
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Tue Jul 07, 2020 11:33 pm    Post subject: Reply with quote

2bims wrote:
Looking lovely Brian....although I was dissappointed that there are only 3 pictures....and as such you now suffer the punishment of me pointing out that you cheated...and only cleaned up the front face of the rear disc...shame on you.....and.....theres a couple of black marks on the alloy rear brake caliper hanger/spacer that should buff up and out with some metal polish......now get busy....


Maybe.... maybe not

The in-hex started to strip out of the first two button head fasteners that I attempted to remove from the rear rotor, and the others are just as tight. I may go back and get serious with them, not sure yet.
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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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2bims



Joined: 03 Apr 2010
Posts: 7289

PostPosted: Wed Jul 08, 2020 8:10 am    Post subject: Reply with quote

TO be fair....I wouldnt normally touch the ones holding the alloy carrier onto the hub....as yes...they will round out as they are made of cheese....I slotted mine with a mini dremel and then cold chiselled them out...and renewed them...but...I was stripping the rear wheel and having it powder coated, new bearings etc......For any bimotas that have the Oscam wheels and the additional alloy rear carrier that the disc bolts to...I'd just remove the carrier to disc bolts.....but again....your other side of the rear disc would clean up just with brake application under use when riding....and...its only a rear disc
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 9:54 am    Post subject: Reply with quote

2bims wrote:
TO be fair....I wouldnt normally touch the ones holding the alloy carrier onto the hub....as yes...they will round out as they are made of cheese....I slotted mine with a mini dremel and then cold chiselled them out...and renewed them...but...I was stripping the rear wheel and having it powder coated, new bearings etc......For any bimotas that have the Oscam wheels and the additional alloy rear carrier that the disc bolts to...I'd just remove the carrier to disc bolts.....but again....your other side of the rear disc would clean up just with brake application under use when riding....and...its only a rear disc


Jeez 2bims, it almost sounds like you’re letting me off with a warning. I haven’t tightened the rear axle yet so I might Revisit it yet.
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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 10:00 am    Post subject: Reply with quote

Carb time..... I’ve been putting this job off for a while, but the time has come to get these carbs stripped, cleaned and put back together.

These things are DIRTY!












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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 10:22 am    Post subject: Reply with quote

I always right down all of the jet sizes and settings etc when I strip a set of carbs. Strange that one carb has a 125 main and the other has a 122.5 main. Float heights were quite different too.

I’ll put the same jets back in, set the float heights both at 12mm and see who it runs.


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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 11:19 am    Post subject: Reply with quote

Carburettor Soup!




Very happy with how the carbs came up after a bath in the ultrasonic cleaner.










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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 11:28 am    Post subject: Reply with quote

On inspection, I found tear in one of the vacuum diaphragms. I have a spare set of carbs that came out of my first DB4 a few years ago... same slides/ diaphragms, so the spare carbs will donate their good slides to the cause.

This is reason I don’t throw anything out.... I have broken shit stuffed away in boxes everywhere Shocked

Of all of the carbs I have stripped over the years, his is the first time I’ve ever had a torn diaphragm, but I always check them carefully.

The other diaphragm in the J carbs felt weird as well, so I changed both of the slides.



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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Wed Jul 08, 2020 11:36 am    Post subject: Reply with quote

I totally forgot to order some new seal kits for these carbs. So again, from my stash of ‘good’ second hand parts from previous carb jobs, I found better seals.

Ready to go back into the bike


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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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welshlamb



Joined: 09 Mar 2011
Posts: 592
Location: South Wales , Nr. Abergavenny

PostPosted: Wed Jul 08, 2020 10:54 pm    Post subject: Reply with quote

Allow yourself a quick back slap or two after that bout of positive activity. Looking good!
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Not as many bikes as I would like and already too many to keep up with!
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Thu Jul 09, 2020 10:39 pm    Post subject: Reply with quote

welshlamb wrote:
Allow yourself a quick back slap or two after that bout of positive activity. Looking good!


😊 thank you
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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Thu Jul 09, 2020 10:55 pm    Post subject: Reply with quote

The carbs are back in, gotta say, they’re a pretty snug fit in the DB2 frame. I’ve had the carbs out of the DB4 about 300 times and it’s a much easier job.

I hooked up a battery pack and remote fuel tank and it fired up fairly quickly. It ran better than it did before the strip down but it’s not running right. After synchronising the carbs and fiddling with the pilot screws, the mid range and top end seems fine but the idle circuit still isn’t quite right. It idles fine, but it really bogs (almost stalls) off idle and then the revs really hang before eventually dropping back to an idle. Adjusting the pilot screws makes very little to no difference, even right out at about 5 turns out.

The hanging revs indicates a lean condition if I remember correctly? I doubt it has an air leak but I’ll buy some ether or earostart today and double check.

The jetting looks weird (as above) to me, even the pilot jet size, but if anything they should be too rich?

Does anybody have a clue as to what the stock jetting should be on a 400ss. I have t been able to find out any information on the internet. I can’t even find a workshop manual for a 400ss.
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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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Bud977



Joined: 03 Mar 2013
Posts: 525
Location: Sydney

PostPosted: Fri Jul 10, 2020 9:42 pm    Post subject: Reply with quote

Carbs came out great Brian. I've gotta get myself one of those ultrasonic cleaners one of these days. How big is your one?

Good pick up on the torn diaphragm. It would have run like shit with the torn one.

As for the poor idle, I'd reckon the pilot jets are still dirty. Very small orifices that plug up, particularly with the rubbish fuels we get these days that don't like sitting around. I use guitar strings to clean them, or you can get oxy welding tip cleaners that are small enough.
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brian



Joined: 22 Aug 2011
Posts: 3769
Location: Australia

PostPosted: Sat Jul 11, 2020 12:37 am    Post subject: Reply with quote

Bud977 wrote:
Carbs came out great Brian. I've gotta get myself one of those ultrasonic cleaners one of these days. How big is your one?

Good pick up on the torn diaphragm. It would have run like shit with the torn one.

As for the poor idle, I'd reckon the pilot jets are still dirty. Very small orifices that plug up, particularly with the rubbish fuels we get these days that don't like sitting around. I use guitar strings to clean them, or you can get oxy welding tip cleaners that are small enough.


My ultrasonic cleaner is the 22ltr version. Just big enough to fit a stripped bank of 4 carbs in. It’s just a Chinese one off eBay.

Pilot jets are definitely clean. Although the pilot jets do seem very big to me. Doesn’t really make sense though as it’s acting like it’s lean in the idle circuit. Pilot screws make little to no difference no matter where they’re set. I’m wondering if the pilot jets are so big that they’re flooding the idle circuit and making the pilot screws useless? I have some other jets and carbs laying around so I’ll keep fiddling
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'99 DB4 #104, '96 SB6 #1165, '94 DB2 J #652, '99 DB4 #088, '08 VTX1800, '93 ZXR750R M1, '95 ZXR750, '95 ZXR750 Race Bike, '94 CBR400rr NC29 Race Bike, '94 CB250, '49 BSA C10 250, '61 BSA A10 650, '89 ZXR750, '91 Ducati 851
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