HELP! Mikuni VM24SS problem...

FastDoc · 08-06-2012, 10:47 PM

On my 2005 Kawasaki Bayou 250 ATV.

The cable operated enricher plunger is stuck somehow to the carb body. Some water mast have gotten in there last ride (in January, playing in the snow). It then sat until I moved this Spring and would not start because the 'choke' was frozen due to corrosion.

It's not the cable, but rather the brass plunger is corroded to the aluminum carb body. I tapped it, heated it, and soaked in in Kroil overnight and I can't get it to budge.

Any ideas? Replacement carb? I'd hate to do that for a choke...

If I trash the plunger during removal can I get another?

FastDoc · 08-06-2012, 11:29 PM

OK I got it to move a little. Enough to cover and uncover the little port in the bore, but I have to force it, it would never work under spring tension.

I need to remove it from the carb body somehow and clean and polish it.

Shouldn't it just pull out?

FastDoc · 08-06-2012, 11:33 PM

Stuck part is #16016. $40! 8O

http://www.bikebandit.com/houseofmot...9213#sch301373

Wild_Alaskan · 08-07-2012, 12:24 AM

could you take a picture of it? i have a vm30 (you can have this if it will help) but it has a direct cable enricher plunger, on mine it just pulls out after unthreading the cable holder

FastDoc · 08-07-2012, 11:01 AM

Thanks, WA.

It would be hard to photograph with my camera but you can see the part in the diagram above.

I figure it just HAS to pull out, there's no other way I can identify it was put in in the first place. It's just stuck.

Mine is also cable operated, attached to a lever on the handlebars, so your plunger may be the ticket for me if I trash mine while removing it, which is likely.

I will measure it when I finally get it out.

Replacing it with a thumb operated plunger would be do-able, but it's in a bit of a tough spot to access.

I can get it to rotate with a screwdriver, and I can force it up and down, but I can't pull it out.

I think it may come to drilling it for a self tapping screw and a small slide hammer or lever of some sort.

FastDoc · 08-07-2012, 11:04 AM

Part #16016

http://www.bikebandit.com/houseofmot...9213#sch301373

Sorry I forgot the link in above post.

Wild_Alaskan · 08-07-2012, 11:33 AM

yep looks just like mine, remove the nut and spring and it should slide right out

FastDoc · 08-07-2012, 11:37 AM

OK. That info helps. It's stuck, likely by corrosion. I will have to do what it takes to remove it. If I destroy it in the process I'll measure it and we can see if your's will replace it. Is your's also cable operated, if I understood you correctly?

Wild_Alaskan · 08-07-2012, 09:01 PM

yep via a small drum style cable end

FastDoc · 08-07-2012, 09:34 PM

I think that's the ticket, WA!

I managed to get the old one out and what a PIA. I'd say I have a solid 2.5 hours invested in this little nightmare.

The plunger is damaged and not serviceable. Some of the damage I may have caused removing it. I polished it up and it still does not fit well. I polished the 'bore' in the carb body with a .32 cal bronze bore brush in a low speed drill. Best I can see there is no damage to the carb.

Here is the plunger. Is this what your's looks like WA?

FastDoc · 08-07-2012, 09:39 PM

It measures .962 inches long.

The 'needle' diameter is.080 inches.

The 'barrel' is .314 inches.

The 'top' of the barrel portion measures .309 inches.

If you have one of these WA let me know what you want for it.

Thanks!

Bill

FastDoc · 08-07-2012, 09:43 PM

BTW, how I removed it:

Maybe this will help the next guy. :wink:

I spent a lot of time soaking it in Kroil, and wiggiling it best I could. Initially it was a zillionth of a mm and gradually increased until I could turn it or push and pull it slightly. I kept this up until the cable pulled out...

Then another night in Kroil. After work today I heated the carb body with a heat gun until it was too hot to touch, maybe 160F or so. Then I hit the plunger with some liquid nitrogen spray I took home from the office. This expanded the carb and contracted the plunger. A little more Kroil and a swift tug with a needlenose and pop, out it came. :P

What a drag...

**cheesy** · 08-07-2012, 10:19 PM

The heat and cold probably did more good helping to free the plunger than the Kroil did, but whatever works. I'll have to remember that trick next time I get an aluminum bike frame with a stuck seat post.

Wild_Alaskan · 08-07-2012, 11:04 PM

Mine measures out the same except it doesn't have the needle coming out of the bottom of it. it just ends at the rubber seal so i am not sure if that would work or not. YOu are also welcome to take the entire carb off my hands if you would like :wink: brand new never even had fuel in it.

I can also check these honds 300s i have for the correct plungers if they have the right carbs.

FastDoc · 08-07-2012, 11:26 PM

No worries, WA. It is available on line, just a bit of a rip :? but I'll be glad to have it together. :wink:

08-06-2012, 11:29 PM	#2
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	OK I got it to move a little. Enough to cover and uncover the little port in the bore, but I have to force it, it would never work under spring tension. I need to remove it from the carb body somehow and clean and polish it. Shouldn't it just pull out? __________________ Happy to serve.
	0

08-06-2012, 11:33 PM	#3
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Stuck part is #16016. $40! 8O http://www.bikebandit.com/houseofmot...9213#sch301373 __________________ Happy to serve.
	0

08-07-2012, 12:24 AM	#4
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	could you take a picture of it? i have a vm30 (you can have this if it will help) but it has a direct cable enricher plunger, on mine it just pulls out after unthreading the cable holder __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

08-07-2012, 11:01 AM	#5
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Thanks, WA. It would be hard to photograph with my camera but you can see the part in the diagram above. I figure it just HAS to pull out, there's no other way I can identify it was put in in the first place. It's just stuck. Mine is also cable operated, attached to a lever on the handlebars, so your plunger may be the ticket for me if I trash mine while removing it, which is likely. I will measure it when I finally get it out. Replacing it with a thumb operated plunger would be do-able, but it's in a bit of a tough spot to access. I can get it to rotate with a screwdriver, and I can force it up and down, but I can't pull it out. I think it may come to drilling it for a self tapping screw and a small slide hammer or lever of some sort. __________________ Happy to serve.
	0

08-07-2012, 11:04 AM	#6
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Part #16016 http://www.bikebandit.com/houseofmot...9213#sch301373 Sorry I forgot the link in above post. __________________ Happy to serve.
	0

08-06-2012, 10:47 PM	#1
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	HELP! Mikuni VM24SS problem... On my 2005 Kawasaki Bayou 250 ATV. The cable operated enricher plunger is stuck somehow to the carb body. Some water mast have gotten in there last ride (in January, playing in the snow). It then sat until I moved this Spring and would not start because the 'choke' was frozen due to corrosion. It's not the cable, but rather the brass plunger is corroded to the aluminum carb body. I tapped it, heated it, and soaked in in Kroil overnight and I can't get it to budge. Any ideas? Replacement carb? I'd hate to do that for a choke... If I trash the plunger during removal can I get another? __________________ Happy to serve.
	0

08-07-2012, 11:33 AM	#7
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	yep looks just like mine, remove the nut and spring and it should slide right out __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

08-07-2012, 11:37 AM	#8
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	OK. That info helps. It's stuck, likely by corrosion. I will have to do what it takes to remove it. If I destroy it in the process I'll measure it and we can see if your's will replace it. Is your's also cable operated, if I understood you correctly? __________________ Happy to serve.
	0

08-07-2012, 09:01 PM	#9
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	yep via a small drum style cable end __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

08-07-2012, 09:34 PM	#10
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I think that's the ticket, WA! I managed to get the old one out and what a PIA. I'd say I have a solid 2.5 hours invested in this little nightmare. The plunger is damaged and not serviceable. Some of the damage I may have caused removing it. I polished it up and it still does not fit well. I polished the 'bore' in the carb body with a .32 cal bronze bore brush in a low speed drill. Best I can see there is no damage to the carb. Here is the plunger. Is this what your's looks like WA? __________________ Happy to serve.
	0

08-07-2012, 09:39 PM	#11
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	It measures .962 inches long. The 'needle' diameter is.080 inches. The 'barrel' is .314 inches. The 'top' of the barrel portion measures .309 inches. If you have one of these WA let me know what you want for it. Thanks! Bill __________________ Happy to serve.
	0

08-07-2012, 09:43 PM	#12
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	BTW, how I removed it: Maybe this will help the next guy. :wink: I spent a lot of time soaking it in Kroil, and wiggiling it best I could. Initially it was a zillionth of a mm and gradually increased until I could turn it or push and pull it slightly. I kept this up until the cable pulled out... Then another night in Kroil. After work today I heated the carb body with a heat gun until it was too hot to touch, maybe 160F or so. Then I hit the plunger with some liquid nitrogen spray I took home from the office. This expanded the carb and contracted the plunger. A little more Kroil and a swift tug with a needlenose and pop, out it came. :P What a drag... __________________ Happy to serve.
	0

08-07-2012, 10:19 PM	#13
cheesy Moderator Join Date: Jul 2010 Location: Elburn, IL Posts: 6,120	The heat and cold probably did more good helping to free the plunger than the Kroil did, but whatever works. I'll have to remember that trick next time I get an aluminum bike frame with a stuck seat post. __________________ Cheesy ______________________________________ 07 Hi Bird Enduro-Flown the Coop 07 Ural Gear Up 79 Honda CX500 77 VeloSolex 4600 V3 73 VeloSolex 3800 I'm making this up as I go.-Indiana Jones Telling me something 'is for my own good', is a fast way to a fat lip.-Me I don't even care about my own problems, why should I care about yours?-Quote on one of my favorite t-shirts
	0

08-07-2012, 11:04 PM	#14
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	Mine measures out the same except it doesn't have the needle coming out of the bottom of it. it just ends at the rubber seal so i am not sure if that would work or not. YOu are also welcome to take the entire carb off my hands if you would like :wink: brand new never even had fuel in it. I can also check these honds 300s i have for the correct plungers if they have the right carbs. __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
	0

08-07-2012, 11:26 PM	#15
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	No worries, WA. It is available on line, just a bit of a rip :? but I'll be glad to have it together. :wink: __________________ Happy to serve.
	0