Topic: 550 Maintenance..HELP

[ShovelHeadNed]

I bought my 77 CB550K last month and although it ran very well I could tell that the carbs needed rebuilding and a good once over for the rest of the bike. Here is what I have done so far:

Removed and cleaned carbs
Replaced stock main jets with #98
Pilot jet set to 1 1/2 turns out
Adjusted valves to the suggested specs (Clymer Manual)
Adjusted Chain Cam
Replaced stock 4 into 4 pipes with MAC 4 into 1
Replaced stock bars with lower tracker bars
Calibrated Carbs with an EMGO carb sync kit

When I started the bike to calibrate the carbs I could barely get it hold an idle. I think most of this came from Having a heck of a time adjusting the throttle linkage. I don't know why I am struggling with this but I am finding it difficult to get the throttle to return to original position from WOT consistently (Basically it sticks from time to time and no amount of adjustment seems to make it right).
I finally got the bike to idle on its own so I could calibrate but it looks like cylinder 4 carb will not adjust, that is to say that it doesn't seem to change the gauge needle or change the idle of the bike unless I adjust the slide all the way down, which isn't consistent with the other cylinders. Likewise cylinder 4 on the engine is much cooler to the touch then the others. The bike is also smelling very rich, and I'm now noticing a leak on the valve cover near cylinder 1 and 2, which is unrelated to any of the other problems but adds to my to do list all of a sudden.

Any help on setting this bike right would be greatly appreciated. Also do the Slow jets come out of the PD46 carbs because I can't seem to figure out how they do. I imagine they are just pressed in but I can't seem to get them out so I figured I would check first to see if what they trick is.

THanks

[bender01]

I believe that one slide on those newer carbs don't adjust. You set them as close to that one as possible initially. I thought it was #2.

[ShovelHeadNed]

You are correct in that the #2 carb is a reference carb although my #4 carb seems to be the problem. I will probably pull the carbs again a recheck everything again but I'd like to get it right this time since it's a PITA.
The bike is running so much worse then when I started this project it has me concerned so I need to find the culprit

[bender01]

Are the slow jets the female ones that open up into the slide? I use something wooden and press down. I also have soaked the rack in a pickle bucket a few times once in Diluted simple green before I figured out that they came out!

[Dimitri13]

If your throttle isn't returning smoothly and binding, then they're either routed wrong, or need to be lubed or replaced.

Did you remove the emulsion tubes and clean them? They're the ones under (when the carb is upside down and you're fiddling in the float area) the main jets in the center. You can see the tip of it when you look into the throttle bore. I use a 4 or 5 mm allen bit in a screw driver to tap them out from the top.

Did you forget any jets (I did once )? Did you blow out ALL the passages with compressed air and carb cleaner? Are the pilot (idle mixture) screws set to factory, 1-1/2 turns out (from lightly seated)?

Did you bench sync them? To do so, the easiest way is to get a 1/4" drill bit, stick it in the bore on the side where the slide is higher (been so long I can't remember which side), and adjust the slide to that. One side of the slide should be barely above the bottom of the bore. Some people shine a light into one side and adjust the slide so that there's barely a sliver of light.

[ShovelHeadNed]

I removed and cleaned the emulsion tubes, and all other jets except I did not remove the slow jets because I am unsure how they come out. I did clean them with fine wire to ensure the passage is clear, but don't feel confident unless I can get them out. I set the pilot screw (Air/fuel mixture) to 1 1/2 turns out, and installed #98 jets.
I am concerned about cylinder number 4 staying cool opposed to the other cylinders, so it's almost as if it isn't getting any fuel or not nearly enough.
Looks like I will be taking the carbs out again and repeating the process. If someone can give me a tip on getting those slow jets out I will just replace them so I can be certain they are up to snuff otherwise I will have to clean again to the best of my ability.

[mickwinf]

slow jets on these carbs are a very tight push fit, a pair of molegrips and pull and twist. new ones are available from sirrius in Canada

[Stilltime]

I have a '78 with the PD46C carbs, but similar setup.  I gripped the slow jets with pliers with a rag around the body of the jet, twisted and pulled straight out.  The slow jets were almost completely clogged on my bike.  You may have loosened up debris that is now lodged in the jet since you said it's running worse now...?  These will have a large effect on your idle, as well as making sure the emulsion tubes are completely cleaned out.