Fit a nut over the screw so that you can hold it in a vice and it will also allow you chase the thread when you remove the nut.This guide is for a set of Mikuni BDST carburettors from a Yamaha FZR400RR 3TJ1.However, it could be useful for other models that use these carburettors.
When disassembling your carbs, take as many photos as necessary. Mikuni Carburetor Rebuild Instructions Manuals Do NotNote that most parts books and manuals do not show the details of the parts and assembly of the carburettors when they are separated. Most of them will show all of the internal jets and parts, but very little of the external fittings that are between the carbs, such as springs and throttle shafts. Because they have a long slot to hold the butterfly, they can be easily twisted or bent. Do not use the butterfly as a stop when loosening the nuts on the end of the shaft. If the butterfly screws are tight, usually because they have been staked, then first, seal the carburettor to ensure that no grit can fall into the throat, and use a Dremel or similar tool to grind away the staked section of the screw. Once the screws are removed the butterfly can be very carefully removed. Trying to force it out can damage the butterfly and the carburettor throat. The screws are JIS Cross Recessed they are NOT phillips screws. You must use a JIS (Japanese Industrial Standard) screwdriver. Mikuni Carburetor Rebuild Instructions Drivers For TheYou must also have well fitting blade screwdrivers for the various jets. We suggest either rubber grease or silicone (spray or grease). All images in this guide follow this format, so left does not necessarily mean the left side of the image but rather the left side of the carburettor as described. You should also expect that small parts like springs, screws jets and washers may fall onto the floor area and that you will need to find them. In this image I have marked cyl 4 on the bottom half of the butterfly. Now it will be possible to put it back in exactly the same position. In the picture you can see how this would be done if you could rotate the butterfly sufficiently to enable your supporting rod to fit flush. If you have to come in at an angle then grind a profile on the end of your support bar to match the angle of the throttle shaft. Done correctly this will enable you to exert maximum downward pressure on the screws and you will be able to remove them. ![]() Ultrasonic cleaning has become very popular, and is the preferred. This section is here because if you plan to stake then you must prepare the screws first.
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