Question about 1993 Yamaha XV 535 Virago DX

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I am having a go at making carb. needles for an XV535, need to know taper dimentions for 5DZ9 and 5DZ10 needles thanks.

I am intend to use siver brazing rod as the needle as it is about the same hardness and is the right diameter.

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  • Yamaha Master
  • 47,290 Answers

Hi, Carl for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
ViragoTechForum com
Carburetor Set up 101
Yamaha XV 535 DX Virago Service Manual
OEM parts for Yamaha

Posted on Jan 08, 2017


6 Suggested Answers

  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

A 6ya expert can help you resolve that issue over the phone in a minute or two.
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The service is completely free and covers almost anything you can think of (from cars to computers, handyman, and even drones).
click here to download the app (for users in the US for now) and get all the help you need.
Good luck!

Posted on Jan 02, 2017

  • 13 Answers

SOURCE: 91 kx 250 stock carb setup.

Low speed screw 1.5 turns out from bottomed. Middle position for clip #3 position.
I never rely on the factory settings for the low speed screww, set it to factory and keep adjusting it 1/8 turn at a time until idle sounds best and quick throttle blips dont sound "stumbly" the later being the most important.

The needle position is for low altitude.

Posted on Jan 26, 2009

  • 190 Answers

SOURCE: Cleaning Carb Jets

not to a trained ear also go by rpm and spark plug color

NOTE: use copper wire to clean jets, sync is just thottles are same position as all carb's just leave them adjustments alone will be fine if are out use a 1/8 drill an place in between piston/butterfly to carb bore to sync/calibrate

better use a manometer for adjusting screws

depends on condition of org parts

worn = richer running

new = lean an clean

also if changed the exhaust system need to
re-calibrate carbs for max performance

Posted on May 09, 2009

  • 4088 Answers

SOURCE: How do I re-jet my carbs?

Basic setting for idle adjustments is ~1-1/2 to 2 turns CCW from CW stop. New stock (paper) air filters don't require re-jetting--only K&N foam replacements require one size bigger main jet. Adjust each carburetor idle screw for smoothest idle. Each screw should be about the same adjustment--if one is non-responsive, that carburetor may need internal cleaning. Make sure you have good spark plugs and the ignition points are clean and set to proper clearance. The ignition coils on these old Honda's were typically weak--try to find a modern replacement. The carburetor slide needles should have the 'C' clips in the center groove. Make sure the retainers are down tight. Check the engine valve clearances (about 0.003 " cold) for both valves when the crankshaft is set for TDC when that cylinder is coming up on compression.

Posted on Aug 11, 2009

  • 3567 Answers

SOURCE: need setting for carb. adjuster on bottom of carb

Turn the adjusting screw all the way in until it LIGHTLY seats. Now back it out one and one half turns. Do the same adjustment for the throttle screw on the right side of the carb. You are now back to the stock factory settings.

Could you take a moment and rate my answer? Thanks!

Posted on Sep 20, 2009

  • 1857 Answers

SOURCE: want to rejet my carb on '07 vt750C2 spirit. Have

to start with you need to purchase a jet kit. it will come with instructions. the stock needle is non adjustable. also you need bigger jets.

Posted on Jun 02, 2010

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1993 waverunner bogging down on take off. New rebuilt carb, will low oil level cause this? Is there a low level switch /?

Only of you have ran the engine out of oil...Sounds like the carbs may not be set correctly.. .Did a professional do the rebuild?..What exactly was "rebuilt".. were any parts replaced?
Sounds like the low speed (pilot jets/air screw passages may not be clean as they need to be??)
Please check the compression on each cylinder..remove the spark plugs... hold the throttle (carbs) wide open when you check this.. spin the motor for 5-8 seconds... you should get 120psi. minimum..(and less than 10psi difference).. if less, it might be time to actually rebuild the top end..(new pistons/rings/hone cyl.).. only bore it if absolutely necessary.. get it measured..

There are only 3 parts in a two-cycle carb that ever need to be replaced,,(unless they are actually broken) The needle and seat assy., the jet needle and the needle jet. ..see pic... parts # 41 = needle and seat assy. #6 = jet needle, #37 = needle jet.


The needle and seat regulate the flow of gas into the carb as the floats rise and fall..,, if they are damaged or leaking the carb will overflow with gas., the needle jet is a orifice with a specific size..The jet needle has a specific size, taper, and length..== The jet needle and needle jet work in unison to regulate the flow of gas from right off idle all the way to WFO..the needle jet/jet needle WILL wear over time causing the fuel/air mixture to become richer and richer and start fouling spark plugs..(this is more pronounced on 4-cycle ATV's)...
I hope this has shed some light on your carb situation...
Good luck...
exploded view of mikuni carb Google Search

Jul 10, 2017 | Yamaha Waverunner Xl 800 / Xlt 1200 Jet...

2 Answers

It's leaking fuel out of the carberatetor ,on a 18hr Kohler engine

usually means you have to replace the carb and get the gasket with it. when the needle valve develops a problem they don't intend for you to fix it. this has been my experience.

Jun 24, 2017 | Kohler Electrical Supplies

1 Answer

My kymco leaks gas from the overflow on the bottom of the carb constantly I have cleaned the carb many times and tried to adjust it at the needle valve but still leaks from the overflow

Hi Shannon:
- Needle valve has been compromised, possibly held open with grit.
Carefully dismantle and blow out all orifices with compressed air.
- Float level set too high. Review the way the float shutoff mechanism works. Make sure the float moves up and down easily and that it still floats as intended. Double check the lever that moves the needle valve. Make sure it is correctly connected to the needle.
Reply as a COMMENT to this post to let me know what you find.

Feb 22, 2016 | Kymco 2010 MXU 375 IRS 4x4

2 Answers

I have a 1985 virago 700 gas comes out exhaust i rebuilt carbs new needle and seat new intake rubbers still having same problem

Hi, Anonymous gasoline in the exhaust not good for this situation I would call my local dealer or reputable shop's service/parts department and inquire about any possible quick fix, answers, or parts inquiry. For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
ViragoTechForum com
Gas coming out of exhaust help
Yamaha XV535 Owners Workshop Manual
OEM parts for Yamaha
YAMAHA XV535 Owner Manual

Jun 25, 2012 | Yamaha Motorcycles

1 Answer

FOR YAMAHA XV535S CARB witch needle goes in the front carb as the needls have differant part numbers [1997 model THANKS Ramon Mitchell

Hi, Rymnm for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Yamaha, despair not, for a mere $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
Cleaning Out The Virago Carbs
Virago XV535 carb
Yamaha XV 535 DX Virago Service Manual
OEM parts for Yamaha

Jul 03, 2011 | 1998 Yamaha XV 535 Virago DX

1 Answer

Gas from the tank runs through the engine (when the motor is off)

Hi and welcome to FixYa, I am Kelly.

You can fix this yourself.
(Turn off the fuel selector)
Remove the carb float bowl nut and bowl. Note the gaskets upper and lower. Remove the float pin retaining the float and drop the float and float needle together.
Briefly turn on the fuel selector and then back off. You are flushing debris from the float needle seat. It is a good idea to use carb cleaner to ensure that the float needle seat area is clean.
ALSO spray carb cleaner into the threaded area where the bowl nut attaches. Your cleaning off the metering jet orifice up inside the threaded area.
INSPECT the float needle itself. The rubber tip should be tapered and pliable. If there are any nicks cuts or debris on the end of the needle first wipe it off and determine if you need a replacement float needle.

Reinstall float and needle ensuring you have the float pin properly installed.
CLEAN the bowl NUT along with the float bowl. Then reinstall the the float bowl. 2 gaskets upper and lower must be properly seated.

Turn on the fuel selector...
Test for leaks.

This should fix the leak but... if you still have the problem and did not change the float needle and seat. Change them. The float needle seat can be difficult to remove. I find that air in the fuel supply manifold fitting will blast most of them out but... sometimes I have to use a drill bit the size of the hole to cut the rubber material and then dig it out with a scribe or jewelers screwdriver. Just make sure to clean the hole with carb cleaner before installing the new seat. To install the new seat... reverse the drill bit using the flat chuck driven end and press it into place. Works great!

Thanks for choosing FixYa,

Apr 22, 2011 | Honda 2500 PSI Gas Pressure Washer

1 Answer

Briigs and stratton 6.75hp runs but has gas streaming out of the carb. this is mounted to a troybuilt generator. Does this sound like a stuck float or a problem with the needle valve?

Hi and welcome to FixYa. I am Kelly There is most likely debris in the needle and seat. This in turn causes the resultant fuel bowl overflow. Remove the bowl, unscrew the float hinge pin screw (note the installed position) and remove both the float and the float needle. Then using something like a spray paint can lid allow the fuel from the tank to flow briefly. You can use a toothpick or jewelers screwdriver to clear any obstructions if necessary. INSPECT the float needle. It should have a nice taper to a point rubber tip. If the rubber is nicked our deteriorated it will have to be replaced.
Once you reinstall the float and needle (making sure the hinge pin screw is secured), test the float. It should shut off the fuel as the float is GENTLY raised to the level position. If it does not shut off you will need to change the needle and seat. Getting the seat out of the carb can be a challenge. In the shop we use compressed air into the gas line connection and hold the thumb over the needle hole tight but allow minimal air to pass through the hole. The rubber seat USUALLY floats up to the surface of the hole opening. If that does not work then we used ground off (straight end) drill bits to extract them. Installing the new seat is best accomplished by using the **** end of a drill bit.

This should stop your carb overflow problem. If you need help with parts information please pass your engine type model number.

The part number for most Briggs & Stratton needle and seat assys is 398188

Thanks for choosing FixYa.


Jul 30, 2010 | Briggs & Stratton Electrical Supplies

1 Answer

How to i find the slides over the throat of the carb to get to the jet needles... im having the same pproblem you solved but dont know where anny of the stuff you mentioned is.. you said move the sliders...

The slides are the bits inside the carbs that "slide" up and down when you work the throttle. The needle hangs in the centre of the slide on a clip, the needle will have about 5 grooves machined in it, The needle is small about 3mm in diameter and it is tapered towards the bottom. if you move the clip one groove down, the needle will sit higher and let more fuel through and visa versa. to get to these you have to unscew the tops of the carbs, its a little hard to explain the whole process by writing it down and there will be some small parts to fly off and lose, please make sure the throttle snaps back to idle properly before you test ride it

Mar 30, 2010 | Yamaha YZF-R6 Motorcycles

1 Answer

Gsf 600 bandit carburettor dimentions . want to do away with the old air fillter box and fit cone type air fillters onto the back of the carb but need to know the diam mentions of the back off the carb...

get yourself a set of cheap calipers from autozone to figure it out for sure, be aware that by changing the filters, you might need to change the carb jets to accomodate the different amount of airflow that you will expierence. Ussually it will take a two step larger jet then what was on it, but not always.

Oct 03, 2009 | 2002 Suzuki GSF 600 S Bandit

1 Answer

Just bought a 82 xj650. It has some flooding on the right carb. any suggestions? Gas comes out the right side exhaust, also dies after running about 10 to 15 minutes.


1.Remove the Float Bowl, (Turn gas off first), and clean the crud out of the bowl. (Bottom of the carburetor)
There is a brass nut in the middle of the float bowl, which is on the bottom of the carburetor.
There is a fiber, or brass washer on that bolt. DON'T lose it! (Turn it to the left)
The brass bolt, (Main Jet Plug), goes through the float bowl, and into the Main Jet.

Remove the float, (Carefully! If it's a plastic designed float, Don't nick it with your fingernail/s. Also make sure it isn't soaking up gas. If so, {You'll know!}, replace it)

A.DON'T let the float needle valve fall out, when you remove the float! The Float Needle is attached to the float, with a small 'hair spring' clip.

B.DON'T lose the tiny, 'hair spring' clip, that attaches the float needle to the float.
Observe VERY carefully how this tiny spring clip goes on the float, ->Before you remove the float pin. (The float rotates up, and down, on this long round pin) It has to be put back the same exact way)

Handle the float with extreme care. It is set to a certain height. The measurement goes from the bottom of the carburetor body, (Where the side of the float bowl touches), to the top edge of the float.

The top of the Float Needle has a groove cut around it. That 'Hair Spring' clip I described above, clips in this groove. The other end of this 'Hair Clip', goes around a flat area that extends out of the side of the float.
Once you get the float bowl down a bit, you'll see what I'm referring to above.

C.The Float Needle Valve is made of metal, and has a Neoprene, (Like rubber), tip on the end. The Neoprene tip is cone shaped. A light little ring mark on the Neoprene tip is okay.
If the tip is broken, or mushed out, the Float Needle Valve is no good.

More than likely you just have crud in the float bowl, and it is also down in the Float Needle Valve Seat.
(The Float Needle Seat is a brass cylindrical shaped piece. It has a tapered hole inside, down at the bottom. Fuel, {Gas} comes through this tapered hole, and the Float Needle Valve regulates how much. The float raises, which raises the float needle valve. Fuel comes through the tapered hole. The float drops, which lowers the float needle valve, and stops fuel from coming through the tapered hole, and into the float bowl)

After time, the bottom of your gas tank develops rust, from moisture in the gasoline.
Dirt also finds it's way into a bike's gas tank. Also the additives in gasoline accumulate after a while.

If you do not have an inline fuel filter, I advise you buy, and install one. This way you change the fuel filter element, and do not have to tear the carb/s down again.

Aug 07, 2009 | 1981 Yamaha XJ 650

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