Question about 1986 Yamaha FJ 1100

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Setting float level on HSC40 Hitachi carburetors on 1986 Virago

I put new carburetor kits in my 1986 Virago 1100 motorcycle and am
having trouble getting the float level right.I have removed and replaced
the carburetors five times and still can not get them right.Is there a
way that I can measure the float level while I have them off?

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I have a 1982 Virago 750 that I just did a carb rebuild to. To set the float levels I built a jig from wood that simulates the position of the carbs when mounted on the bike. This jig clamps into my bench vise. I created a fuel supply using a small funnel and a piece of fuel hose mounted above the level of the carbs.. After that all you need is a short length of transparent fuel hose to attach to the drain on the bottom of the float bowl to provide the visual indication of the float setting. Now you are ready to set up the float levels on your bench. This is way easier than trying to set them up in the bike.

Make sure that the jig is set up so that the carbs sit as level as possible across the pair and that they sit as close to the natural position in the bike in the lengthwise position when the bike is sitting level.

The process of setting up these floats can be very tedious, be patient. It may require that the float bowls be removed multiple times to get it correct (I replaced the philips head machine screws with allen head screws to make this easier). Printed instructions for the procedure look for a certain fuel level setting plus or minus 1mm. This kind of tolerance can be quite difficult to get when the only adjustment you have to work with is to bend the metal tang on the float assembly.

Posted on Jul 09, 2009

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Posted on Apr 18, 2009


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I have a 1986 yamaha virago 1100..when I first start the bike and put it into gear it dies out...when I rev it to 7000 rpm it goes into gear and is fine for the day until the next day

Hi, Floyd and the usual suspects are:
1. Idle circuit and transfer ports clogged.
2. Air fuel mixture adjustment too lean.
3. Pilot jet clogged.
4. Faulty accelerator pump.
5. Float level too low.
6. Float bowl contaminated old fuel, water, dirt, rust, etc.
7. Float bowl vent or overflow tube clogged.
8. Fuel flow to carburetor restricted.
9. Intake manifold leak.
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What is the float adjustment on the carb I know how I just need the measurement on it

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- Now days some carburetors are produced which are fixed and no adjustment is provided.The float is made up of whole plastic like material.
Some floats have the copper/metal notch for the adjustment of fuel level.
- Take the carburetor assembly out.
- Remove the fuel bowls.
- Place the carburetor assembly with the floats upward towards yourself.
- Float level gauge and active data list (taken from the workshop manual) is required to carry out the adjustment. But you can simply adjust the float level correctly without any gauge.
- Hold the carburetor assembly at your eye level in such a way that the carburetor No. 1 is in front of you. Behind is No. 2 carburetor, then behind is No. 3 and then the No. 4. Or we can say that the carburetor No. 1 hides the carburetors 2, 3, and 4.
- Examine carefully the floats of all the individual carburetors be parallel to the surface of the carburetor where the float bowl face is seated and tightened.
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My first guess would be the float bowl for the carburetor. The fuel level needs to be maintained at a specific height in the bowl. There's a float inside that activates a valve which allows fuel to fill the bowl - once the correct level is reached, the valve closes. On my old Virago there were simply two tangs inside as I recall that needed to be bent manually to make the adjustment. To check the level you would attach a piece of clear tubing to the drain port on the bottom of the bowl.....when the drain was opened the fuel would fill the tube to the same level as is in the bowl. You would need to find the correct spec for that level and adjust if necessary.

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Hi, Jdease the answer to this question is way above my pay grade and 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.
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Hi, Dale and the usual suspects are:
1. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a load test if necessary.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Spark plugs in bad condition or partially fouled.
4. Spark plug cables in bad condition and leaking check for spark leakage in the dark
5. Spark plug gap too close or too wide.
6. Faulty ignition coil, module, and or sensor.
7. Loose, dirty, or corroded ignition module connector at crankcase.
8. Faulty CKP or CMP, MAP, ETS, ATS, TPS, O2 sensor.
9. Dirty air filter.
10. Intake air leak.
11. Water, dirt, or rust in the fuel system.
12. Carburetor damaged, contaminated, sticky float, plugged jets.
13. Multiple carburetors out of sync.
14. Fuel filter clogged.
15. Old or contaminated fuel.
16. Fuel tank vent system plugged or carb vent line closed off.
17. Gas cap diaphragm valve faulty.
18. Vacuum line from intake manifold to fuel valve is broken, cracked, pinched, or missing.
19. Carburetor controls misadjusted.
20. Incorrect valve timing.
21. Valve springs floating, weak, or broken.
22. Damaged intake or exhaust valve.
23. Incompatible performance parts.
24. Control module may be in "LIMP" mode
25. Check for engine trouble codes.
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.
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Sounds like you will need to clean your carburetor.
Be sure to use compressed air to blow out all the fuel and air passages.
After cleaning and before you reassemble the carb, be sure to "set" your float level, turn the carb upside down and make sure the float is LEVEL and not tilting up or down
Sometimes you can get by with priming the carburetor a few times, and letting it run a few times like that and it will flush the gunk out of the jets,but most of the time you will need to rebuild the carburetor.
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When you clean your carburetor and remove the jet screws, You will first seat the jet screws and count the number of turns it takes to seat the jets from their original position.
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Please rate me

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Good luck...i hope this helps.

Jul 28, 2009 | 1986 Yamaha FJ 1100

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