Motorcycle Repair: Carb and brake rebuild, blade angles, suzuki gs550es

Question
My bike (1986 Suzuki GS550ES) has been sitting for a couple of years (covered in the garage) and it's time to get it back into shape. I was reading through some of your responses to other questions and saw that you offered some detailed files for cleaning and tuning carbs. I was wondering if I could get those from you? I've rebuilt the carbs using the Haynes manual for the bike, but the bike boggs in the lower to mid range rpms. From all that I've read it seems that I need to start by adjusting the float heights and then the pilot screws.

I don't mind adjusting the float heights,but my pilot screws are fairly stripped. Is there a good way to get them out without damaging the carb body?

I an also looking for some help in rebuilding my front calipers on the motorcycle. I've rebuilt them once and they are still not fully releasing. I replaced the internal seal and dust boot, but think that there might be to much corrosion in the caliper. What would you recommend I do to remove the corrosion. Ideally I would like to chemically remove it, but I have a feeling that I will have to sand it down.

Thanks,
Moshe

Answer
Hi Moshe,

I have the same bike (customers) with the same problems right now.


I can send the necessary files, but need a email addy as requested. Send to: mshively1@woh.rr.com

I plan to have a machine shop remove the pilot screws on my customers MC.

Clean the dried brake fluid from inside the brake caliper before installing new seals. I fabricated a cleaning tool from an Allen Wrench. I ground the ends to appear as a flat blade screwdriver. I observed the blade angles to best fit the caliper seal grooves, and my hand positioning while cleaning, and then ground the ends. Another guy made his tool from a pop-sicle stick.

Respectfully,
Mark Shively