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  #1  
Unread 08-21-2008, 08:07 AM
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Kokamo Kokamo is offline
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Default **HOW-TO** Carb Clean 97' CBR 600 F3

My apologies that the first thread go deleted, my bad, trying to make things better and I wiped it out somehow. If you have any questions re-ask them and I'll reply back.

Ok guys, I haven't seen a good carb "how to" here, so I thought since I was pulling the carbs on my 97' F3, I would utilize my brand new camera and make one. Keep in mind, some of the pics are a little blurry, but when you get to that point of the picture, you will understand my explanation. Also keep in mind, I will talk you thru this the simplest way I can. That means I will be using NO SPECIAL TOOLS, and doing this WITHOUT taking your bike to a shop to have someone do something....other than a carb sync). Everything you read can be done with basic knowledge, you don't have to be a certified mechanic to perform a carb clean. Just take notes on how anything questionable comes apart.....if all else fails, take pictures. Hopefully I've posted enough pictures to help pretty much anyone out. Also, I will not be using technical names on any of this how-to, so any regular ole guy will understand what I am talking about. Pictures will be posted via clickable link inside the text, so if you see -->THIS<--, underlined, capitalized, and clickable, there will be a picture available.

Ok, here we go........First off, I used THESE TOOLS to take off the carbs. The very first thing you should do, is take off both rear side panels.....anyone should know how to do that. Then you take off your SEAT. My bike used a 12mm socket to take off the two bolts....one on each side. Once the seat is off, the fuel tank needs to come off. There are two bolts that hold the tank on, one in the front and one in the rear HERE. My bike used an 8mm on the front bolt and a 12mm on the rear bolt. Once the tank is loose, there are THREE LINES connected to the bottom of the tank. One is the main fuel line, one small vacuum line, and one large overflow line. All of them must be disconnected. Now the front side panels need to come off. Take side mid panels off with the 5mm allen wrench, then on the LEFT SIDE, there are 6 (six) allen headed bolts which you use the 5mm allen wrench on. It's the same for the RIGHT SIDE....6 bolts. Once all that stuff is out of the way, you can start getting the carbs out.

You should have somthing that looks like THIS. Take out all the screws that hold the air filter assy on and put that aside. Keep in mind that there are three parts to the air filter assy. The two top parts are what hold the air filter itself. The lower part is what hold the entire assy to the carbs. There will be some SMALL TABS over the head of the bolt. They keep the bolt from coming loose and possibly falling into the carb and creating one really bad problem. Simply take your screwdriver and pry them up, take off the 16 screws that hold the lower filter assy off. Don't try to take off the metal (gold) bracket or the velocity stack (silver).....they will all come out with the removal of the lower filter assy. Once thats off, you should have somthing that looks like THIS. There are some black RUBBER O-RINGS that go between the carb and the filter assy. Pull them out and put them in a safe place away from any carb cleaner (they will swell). Then you will take all of your emission lines off, keeping note of where they go. You will also take loose the ignition coils. They are located just in front of the carbs. All you have to do is unbolt two bolts from each coil and it is loose. Unplug the two wires (keeping carefull note of where EXACTLY they go on each coil) then you can push both coils down on top of the motor and out of the way.
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Last edited by Kokamo : 08-21-2008 at 08:12 AM.
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Unread 08-21-2008, 08:08 AM
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Default **HOW-TO** Carb Clean 97' CBR 600 F3 ~~PART 2~~

Next you will take off the CHOKE CABLE with your phillips screwdriver. Then you will need to loosen the FOUR CLAMPS that hold the carbs onto the engine. That's where that long ass phillips screwdriver comes into play. Loosen them generously, but not so far as the screw to fall out. Then you can pull the carbs off the motor. Don't pry if you don't have to....just use your hands....it will come up. If you have to pry, make sure you don't bend anything important.....like the TPS (throttle position Sensor).

Ok, once the carbs are loose from the motor, you will need to disconnect a FEW THINGS from it. You have 2 (two) coolant lines, one SMALL VACUUM LINE, the idle adjustment cable and the two throttle cables. Make sure you don't loose the SPRING AND WASHER from the idle adj cable.

Now your carbs should be loose and sitting ON THE TABLE ready to be cleaned.

THESE are the tools I used to pull the carbs apart and clean. Aside from the carb cleaner and a dremel tool, thats it. Oh yeah, I also have another tool.....it's called a radio.....XM Radio to be exact, and it plays some killer music to make this entire project go quicker....like GEORGE THOROGOOD for instance.

The very first thing you'll do is pull off the TPS sensor on the left side of the carbs so it doesn't get damaged from any carb cleaner. Make sure you get the little PLASTIC PIECE out of the end of the throttle shaft. Your TPS will NOT work without it. Ok, were gonna call the far left side carb #1 and the far right #4. That's just the way I did it and it helps out by keeping all parts in the same carb they came off of....just in case. Just scribe the carb number into the bowl and on the main housing LIKE THIS.

Then you'll take off the CHOKE ASSY by using your phillips on the two screws holding it on. Make sure you note how the spring and washer go back on.

Next, you'll take off the FUEL BOWL by taking out the three screws. It might be a little stuck so take the plastic end of your screwdriver and tap on it gently and it should jar it loose. There was a little junk in my bowl, just make sure you clean it all out before you put it back on. You should have somthing that looks like THIS. You'll then need to take out THE PIN that holds the float into position by pulling it out with a pair of pliers. It should just slide right out. once it's out, the FLOAT AND NEEDLE will fall out.

Next, you will take out the TWO JETS. The small one you can take out with a WELL FITTING flat head screwdriver. Turn it counter-clockwise to loosen. Then you will take out the large jet with the same well fitting flat head screwdriver. Keep in mind that the large jet is a two piece jet. The top part will unscrew counter-clockwise out of the lower part. To get the lower part out, use a 5mm socket (CC as well). There is another jet in there that is press fitted and cannot be taken out. Keep in mind you will need to make sure you clean it very well before it goes back together. Details later on.
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Unread 08-21-2008, 08:09 AM
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Default **HOW-TO** Carb Clean 97' CBR 600 F3 ~~PART 3~~

Go ahead and pull all float bowls out and put all JETS AND PARTS into the corresponding BOWLS they came out of.

Next you will take out the CHOKE PLUNGER simply by using a 10mm socket. Make sure you are very careful not to loose the pre-loaded spring. HERE is the assy. Pull all choke plungers out and put them with the float and bowl assy.

Then you will take out the DIAPHRAM thats on top of each carb by pulling out the three screws. Make sure you are careful not to loose that GIANT SPRING thats inside there. Once the diaphram is out, you can pull the SLIDER out and then again, put it with the corresponding carb.

Next you will need to take out the three LITTLE SPRINGS that go between each carb. These are stubborn little bastards and they can fly off to never-never land if you aren't super careful. Trust me, I lost two of three, but I lucked out and found them. There is also a larger diameter SPRING between carb #2 and #3 HERE. This one you don't have to take out till you separate the carbs, so it can wait till then.

Once you are ready to take the carbs apart, you will need to use an 8mm socket and a 10mm socket to loosen the two nuts on the CROSS BOLTS that hold all the carbs together. Once out, they look like THIS. Now, when you try to separate the carbs, you need to pay close attention to where you pry at. If you pry in the wrong place, you could possibly ruin the carbs by bending or cracking it, so be careful. Look at THIS PIC and THIS PIC to know where to pry them apart at.

Once apart, you should see THIS. I had a few O-RINGS bad on my coolant pipe, so that was something I will need to replace.

Ok, once you get all carbs apart, make note of where all parts that go between the cars go. just in case, I provided some insight to the questionable people by taking a few pics of all hardware.

Carb #2 & #1
Carb #3 & #2
Carb #4 & #3
All carbs and all hardware

Next, you will take off the SMALL DIAPHRAM thats on the side of each carb by using a phillips screwdriver. Pull it off and there will be a BRASS JET WITH AN O-RING on each end. PULL IT OUT carefully. Make sure to get the little o-ring out of the hole next to the jet and put it with the little diaphram. The jet you just took out looks like THIS. Make note of how it comes out of the hole.
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Unread 08-21-2008, 08:10 AM
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Default **HOW-TO** Carb Clean 97' CBR 600 F3 ~~PART 4~~

Next is one of the most difficult parts. You will need to get the MIXTURE SCREW out. This is where a "special tool" is involved, but like I said earlier, you won't have to have that special tool, unless you really want to go out and pay however much for one, then skip this step. The "correct" tool is called a "jet tool". The end of it is in the shape of a "D" on the inside and fits over the head of the mixture screw. The way I took mine out cost no money if you have a dremel tool laying around.

First, you will need a dremel tool, you will need a thin cutter attachment for it. It looks like a small disk grinder....about .015" thick. What you will do is cut a vertical line thru the housing of the carb that surrounds the mixture screw.....actually cutting a groove thru the top of the screw. Make it just deep enough to use a small screwdriver on to pull it out. After you are done, it should look just like THIS. No worries, this won't hurt your carb.....unless you go so deep and get into the threads, then you might have a problem.

Ok, now that you are able to turn out the mixture screw, you need to make certain of EXACTLY where the screws position is. Before you turn it any at all, screw it in until it bottoms out making an exact count of how many turns until so. Mine were between 1-1/2 to 2-1/4 turns on all carbs. Just make a note of where each one is. Once the screw is out of the hole, there will be a SPRING, WASHER, & O-RING and they need to go in that order...just like the pic. Look how DIRTY mine was.

Oh man, SRV on the XM!!!!!

Ok, now that you have the carbs all apart, you can start cleaning them. The best stuff IMO is CHEMTOOL B-12. Just make sure you don't get the shit in your eyes, cause you'll want to die if you do. Burns like a MOTHA!

A few notes about cleaning. Just spray the B-12 in every single hole that's open. WEAR GLASSES cause you never know where it might shoot out at. Be sure to clean the IDLE CIRCUIT. It's the three little hole just inside the bottom of the venturi where the butterfly goes. Also, the jets you took out of the carb....clean them all. They all have holes thru the middle and thru the sides. HERE, HERE, and HERE. Makes sure they are all clean. Use compressed air to blow it all dry real good. Also be sure to clean the needles real good and get any glaze off of them. For instance, the one on the right it clean, and the one on the left is dirty HERE oh yeah, the little press fit jet we talked about earlier.....it has a little-teeny-tiny hole in it and it MUST be cleaned out. If you can push compressed air thru it, simply blow some B-12 thru it and your good. if you can't blow air thru it, it is clogged. Use a small piece of wire from a wire brush to poke down into the jet. Don't work it too much cause you don't want the hole any larger than it needs to be. Just enough to get a little bit of air going thru it.
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Unread 08-21-2008, 08:10 AM
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Default **HOW-TO** Carb Clean 97' CBR 600 F3 ~~PART 5~~

HERE are my CARBS when they are all back together and cleaned up.

To re-install, just reverse the order of this entire how-to.

Ok, that's about it. if I missed anything, simply post here or send me a PM and I'll answer back if I am available. Just take your time, take notes and pictures, go slow and try not to leave it apart for more than a day (memory loss). If you need to get new o-rings, your motorcycle shop should have them, if you can't find a MC shop that has them, go to pretty much any auto parts store and ask them for their assortment of small air conditioning o-rings. Don't get the black generic ones as they aren't all that acceptable to the harshness of gasoline. The AC o-rings should be green, red, blue, or purple. Remember to use some light oil on all parts going back together......o-rings or threads.....especially the jet threads.

Oh yeah, one last one from DEF LEPPARD

Hope this helps you guys out and doesn't confuse you more.

~Joe
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Unread 08-21-2008, 08:15 PM
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Thank you SO MUCH!!! I'm just about to do this, probably next week, I don't think it's gonna be much different between an F1 and an F3. Wish me luck that it starts again, lol.
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Unread 08-21-2008, 08:40 PM
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Qs, no prob man. Yeah, I'd say if it's not the same as an F3, it's gonna be real close. I mean, all general instructions should be somewhat close.

Good luck, post your results!!!

Joe
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Unread 08-23-2008, 04:27 AM
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awesome write up! thanks man!
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Unread 11-23-2008, 11:56 AM
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Man this is a great write up. I plan to do this over the winter. This will save me alot of money. Thanks.
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Unread 02-01-2009, 09:14 PM
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got mine apart tonight. Pray that I can get them back together tomorrow.
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