DR200 Carb problem

[DRider]

I have a 87 dr200 with a mikuni carb. The problem is the throttle pump which squirts gas down the throat of the carb seems to have a stuck piston. The piston is a small brass cylinder in the float bowl which is activated by a pushrod running down the side of the carb. Is there some way to get this piston out or at least to free it up?

All replies appreciated.
Matt

[DRider]

For what it's worth, I fixed the problem myself. I drilled a small 1.5mm (just under 1/16") hole in the top of the piston to about 3 mm (around 1/8") deep and screwed in a small self tapping screw and pulled the piston out. There didn't appear to be any reason for it sticking, but i polished it with fine wet/dry sandpaper anyway. It seems to be working fine now.

[Irwin]

Glad your carb piston is unstuck, I'd be afraid to go drilling into my carb like that. You must be lucky or damn good which ever you prefer.
Got it running yet?
Irwin

[DRider]

There is a bit more to it than just drilling into the carb. I knew from dismantling it before that this piston is solid, not hollow. I clamped the float bowl in a mill/drill and slowly and carefully drilled into it. The biggest problem would have been drilling right through. this would have made it useless, but as I was only drilling about 3mm into a piston that is about 15 mm deep, it wasn't really a problem. I work in an engineering workshop, so I have access to all the equipment needed. This is a HUGE help when rebuilding a bike. I would have saved myself hundreds of dollars.
For example: All the bearings in the rear sespension and swingarm were worn out (too much riding on the beach with no washing down afterwards). Many of these bearings are needle rollers, which are specials (i.e not avaliable from the local bearing shop, only from Suzuki distributors at huge cost and a long wait). I decided that needle rollers were a massive overkill for what I want to use the bike for (fun trailriding and bush bashing) so I turned up my own sintered bronze and plastic bushes. Also, some of the pins (long bolts) were badly worn, so again, I made my own, heat treated them myself and they fit fine. I'll see how they work when the bike is finished.

[Irwin]

If I had the kind of tools you have available, I'd be dangerous.
It sounds like you can remanufacture just about most of the movable parts on your bike--How handy is that!!! Cool!!! Have you seen the Rear Racks Brian makes on E-Bay for $100US. They look nice, I could use one, but I'm having a hard time justifying spending that much at this time.