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Old 07-02-2012, 03:15 AM   #1
Schrauberklaus OP
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How to build dual Flatslide Carbs for Honda XL/XR 600

Hi fellows

After i show photos of my carb conversion on my XL 600 R with TM flat slide Carbs , I have been asked for more details.

In this threat i try to discribe how to fit 2 TM 34 Carbs on a XL 600 RFVC engine over the next weeks.
I need some time to think again through all the necessary changes and label the pictures accordingly.
Then I have to upload them and insert the appropriate description for every pic .
And my english is not perfect .
So please be patient with me .


A few years back i rebuild my XL 600 R and run in to a Problem .

After the XL was ready for test rides i dit this with my workshop tank .
I dit numerous modifications on my XL and want to test if everything holds and works as intended.
This requires not big tank so I strapped a 1 L Lawn Mower Tank to the XL .

This makes everything much easier to access which makes the settings easyer.
Only 1 L fuel does not last very long and if I parked the XL with a nearly empty tank for 2 weeks then the engine would not start again .
After some searching, the cause was found.
When the Bike was parked long enough that all the Gas from the Tank and the float bowl evapurated the Alloy of the Keihin Carbs oxidizes and this withe powder cause the Problems .

If i refill the Tank , the Gasoline washed and rinsed the oxid powders in to all holes and the nozzles and clogged them .
I think I had so 7-8 times the carbs completely disassembled and cleaned. Always with the same result. Were the carburetor clean, the engine started well (1-3 kicks) and also ran very well.

If the Tank was full at the beginning of the Time when i was to busy to work on the XL and it was still Gasoline in the Float bowels when i try to start the next Time then there was no Problem .

But if the XL stand long enough that the fuel in the carburetor could evaporate completely then I had problems to start
the engine .
And then I found again and again the same fine dust everywhere in the nozzles.
And after the carb was clean again all it was alright.

I expected the oxidation of Alloy is direct related with the E10 gasoline sold here in Thailand in the last few years .
The XL was standing for 8 years by the PO and as i get it the Carbs was inside after all this Time more clean as now after a few weeks . But the Carbs had never seen Gasohol befor .

And so the Carbs looked at some of the cleaning action.




With that Problem it will be not possible to close the Gas Taps for long time parking and i need a Solution for this .

Both of my XR's, both were equipped with Mikuni TM carburetors don't have this Problem .
So I chose this carburetor for my XL to .

On the XR 280 I use a TM 36 from which i could take all the dimensions , and according to the measures i know i can accommodate 2 carburetor of this size.
My research led me then to the use of TM 34-B65 carburetors, a double TM for use on a Yamaha Raptor .



And this is the TM 34-B65 in its original state.


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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-02-2012, 03:22 AM   #2
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The cases appear to be based on the same mold as the TM 36, so it was ensured that these fit after the adaptation work in the frame and the motor .

The Target was to make the Mikuni Carbs fit without any further changes to the intake boot or Rubber boots to the Air Filter Box

In order to achieve this are some changes to the Mikuni carburetors necessary.

The Keihin PD Carb front is 38.5 mm diameter , the Mikuni TM is 40 mm in diameter .
Rear, the PD Carburetors is 50 mm and the TM Carbs are 55 mm
In addition, the TM carbs are also a good 10 mm longer than the PD carburetor.
and of course the two TM Carburetors must have the same angle as the PD Carbs so that they fit to sit in the Intake Boot .

As you can see in the photos the TM carburettors have the throttle cable on the left and the accelerator pump between the carbs.

This is not possible on a XL frame.
The XL Frame has left not enough room for the throttle cable and the accelerator pump must be on the outside otherwise there will be no access to the Pump ajustment if the Carbs are installt on the Bike .

The solution is simply to swap the two carburetor body.
The shaft is connected to both slide and must be split anyway to angle the Carbs .

Fortunately, both cases came from the same mold and are designed to stack more then 2 Carbs in series and therefore, all the connections are on both sides in the cast there, but not drilled where they are not needed.
This must be changed to reflect the new configuration.



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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-02-2012, 03:30 AM   #3
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to be continue
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-02-2012, 04:36 AM   #4
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Old 07-02-2012, 05:21 AM   #5
Billtr96sn
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Cool, good work.
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Old 07-02-2012, 06:43 AM   #6
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Thanks for writing this up Klaus

Very much appreciated...........I might start looking for some new carbs
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Old 07-02-2012, 09:29 AM   #7
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Good work, good photos- thanks!
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Old 07-03-2012, 02:08 AM   #8
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to be continue
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Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-03-2012, 06:15 AM   #9
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to be continue
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Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-03-2012, 06:43 PM   #10
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nice work looking for machine work? you seem to do good work and I have lots to do
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Thanks Scrubby
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Old 07-05-2012, 02:09 AM   #11
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Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-05-2012, 02:11 AM   #12
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Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-05-2012, 02:13 AM   #13
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__________________
Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-05-2012, 02:17 AM   #14
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Klaus
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Honda XL 600 R(S) 84 , Honda XR 600 Dual Carb. 87
Honda XR 280 R Sumo 04 , Honda XR 250 Baja 98
Yamaha Speed MX ( 2 Stroke ) 01 ,CRF250L 13
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Old 07-05-2012, 04:14 AM   #15
deejay_xr
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The amount of detail in your build report is amazing Klaus, thanks for sharing !!

Hope you heal up soon and can go riding again !
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