Hi All,

I have a 1987 Samurai with a Hitachi carb. I'm in the process of cleaning the carb and replacing a couple of parts. One thing I am considering replacing is a small rubber "cup" that attaches to the bottom of the mixture control solenoid valve (a diagram of this part can be found on page 4-15 of the Suzuki Samurai Factory Service Manual). I called my local Samurai dealership and although he has many parts for the Hitachi carb, he does not have this cup. Can I simply use a rubber o-ring instead? Any idea if a plain old o-ring from the local hardware or NAPA auto store would deteriorate when exposed to gas? Would folks suggest that I just put the old cup back in and leave it at that?

Thanks for the help!

Cliffhanger_MT

If you want a replacement for it... Give Hawk Strictly Suzuki a call at 1-888-SAMURAI.... If any one would have it, they would.

Zig

Hi Zig,

Thanks for the tip! I'll check it out.

-=Cliffhanger_MT

Update: I talked to the folks at Hawk Stricly Suzuki and was told that the item is actually an o-ring, not a "cup". It is listed 2 different ways depending on which edition of the FSM you look at. The old part I took off is definitely not an o-ring, but I was told that an o-ring should work just fine since that is what is listed for the part in the later edition of the FSM. I'll give the o-ring a try and post whether or not it works. Stay tuned...

Update: Just a plain, ol' o-ring worked fine. My Sammy runs better than ever now that the carb has been cleaned and accelerator pump repaired. It'll actually pull 55+ mph in 4th gear going up a moderate grade. Yea!

Cleaning my carb is this weekends project(plus a little more depending on time),  any pointers?  i have a chilton book but that is about as good as a monkey with a crayon form what i glanced at

Hi Jow003,

Several things:

1. Download the factory service manual here: http://www.acksfaq.com/86-87_410_FSM.htm. The carb section is at the end of Part #1 (the manual is downloaded in 3 parts).

2. Use this guide to help with disassembly: http://bbs.zuwharrie.com/content?topic=21551.0;wap2. It will talk you through an "in place" card disassembly and cleaning. It's supposed to have photos along with the written instructions, but they're seem to have never gotten posted to the page.

3. Take detailed photos of everything before disconnecting any linkages, cables, hoses, or lines.

4. If your carb is still on the vehicle place some kind of tarp under your working area to catch any parts that may fall on the ground (there are lots of small screws, springs, etc.). Also, I placed a sheet around the carb itself (kinda like doing surgery) to prevent dropping and losing parts inside the engine compartment. It may sound like overkill, but if you've ever dropped the critical little (and I mean little) spring that is part of the accelerator pump assembly, you'd appreciate the extra 5 minutes it took to cover the engine compartment with a sheet.

5. Speaking of accelerator pump springs, you will get to a point in the cleaning where you will need to remove parts of the accelerator pump assembly. There are many ways to get these parts out of the carb. One suggestion is compressed air. Don't do it. These parts are so small that even a tiny blast of air can send them flying. I used a set of jeweler's needle nose pliers (very long and thin jaws) to get to as many of the parts as I could. I then used a small piece of chewing gum (you gotta chew it first) on the end of a long and very thin straight-slot screwdriver to remove the lower parts and valve check balls.

6. Get yourself a cheap set of guitar strings which will be used to clean the various passageways and jets in the carb. I recommend getting either light or extra-light gauge strings since the Hitachi carb has several near microscopic passages, ports and jets that will need to be cleaned. You should only need to use the straight steel strings (G, B, and E) and not the brass/bronze wrapped strings for cleaning purposes.

That's it. Proceed carefully, take notes/photos, keep track of the parts. It took me about 2 hours start to finish to get my carb cleaned up and my Samurai runs soooo much better now! Good luck!

Cliffhanger_MT

P.S.- One last thing, most of the crud in my carb didn't come from the fuel system--it came from moisture leaking down the accelerator pump plunger shaft and then settling in the bottom of the accelerator pump chamber where it started to corrode the aluminum of the carb body. That crap then got circulated throughout the carb and clogged things up. I replaced the badly deteriorated boot and all seems fine now.

just reading that scares me   guess no way to learn without doin it lol

kudos to cliffhanger_mt on hitachi carb work discription. an overhaul kit will also have a good break down of parts and a basic diss./reassembly order.
the carb. for my kick is slightly different, but i'm wondering if the mixture control solenoids are interchangeable?
(dealer tells me it's a discontinued item)