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Carburetor Drilled Return Pressure Balancing Modification GPR, XLT, GP, SUV, etc.

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  • Carburetor Drilled Return Pressure Balancing Modification GPR, XLT, GP, SUV, etc.

    I get asked all the time about this modification so I decided to make a "how to" and make it a sticky.

    This is one of the simplest modifications to do to your carbs. It is intended for multiple carb applications, but can be done on a single carb application as well.

    The goal of this mod is tie triple carbs with individual fuel pumps, into a single balanced pressurized system. Rather than three individual systems

    One advantage to this modification has been, reduced fuel pump check valve failure. This is a common problem on the older style SBN carbs, used on the GP1200, SUV and many other skis. This failure can lead to potential lean condition, and piston failure. I ran a set of SBN's with this modification in my SUV, and I had over 300 hours on the carbs. When I inspected them recently, all the check valves were in pristine condition. Pretty much unheard of for these style carbs.
    When I would get a set of SBN carbs in for repair, I could guarantee the cutomer I would find a creased check valve, and I was right 99.9% of the time.

    Another reason for this mod, is the small return orifice in the carb body, gets plugged easily. Either by a foreign object, or corrosion. The orifice is .020" in diameter. This condition results in the fuel pressure getting to high within the carb, which in turn forces the needle valve to open and floods the carb.

    There are several ways to do the restrictor either with a jet installed in an inline fitting (Tee or coupler) or threaded into the tee on the carbs.

    Novi carbs come with the returns drilled out, I will attach their schematic.

    On Yamaha 1100 carbs with the remote fuel pump, the carbs were set up in this manner. They had a restrictor built into the last tee on early models. Later models they went to a small orifice in each cover.
    "Insanity is doing the same thing over and over again, and expecting different results"

    http://www.pwc-performance.com/
    Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

    Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

    http://www.hydrotoys.com/gpr/tuners/osidebil/

    01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
    01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
    02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
    99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

  • #2
    The Return orifice shown on SBN and SBN-I (GPR) carbs
    Attached Files
    Last edited by OsideBill; 07-21-2012, 01:22 AM.
    "Insanity is doing the same thing over and over again, and expecting different results"

    http://www.pwc-performance.com/
    Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

    Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

    http://www.hydrotoys.com/gpr/tuners/osidebil/

    01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
    01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
    02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
    99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

    Comment


    • #3
      Drill the return orifice out, using an 1/8" drill bit. It is not very deep, stop when the hole breaks through into the fuel outlet cavity. The fuel outlet cavity is where the nipple for the return line is either threaded or pressed into the carb body.
      Attached Files
      "Insanity is doing the same thing over and over again, and expecting different results"

      http://www.pwc-performance.com/
      Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

      Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

      http://www.hydrotoys.com/gpr/tuners/osidebil/

      01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
      01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
      02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
      99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

      Comment


      • #4
        Tap the last tee on the #1 carb where the line returns to tank with an M5 tap, the hole is already the correct size no need to drill.
        For GPR's and XLT's, Install a 95 Mikuni Main Jet
        For older GP's and SUV's use a 105 Mikuni Main Jet. 97-99 GP1200's have a smaller fuel line so it is necessary to either change the fittings or use an inline restrictor.

        By insatlling the restrictor Jet in this fashion the Mod always stays with the carbs
        Attached Files
        "Insanity is doing the same thing over and over again, and expecting different results"

        http://www.pwc-performance.com/
        Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

        Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

        http://www.hydrotoys.com/gpr/tuners/osidebil/

        01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
        01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
        02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
        99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

        Comment


        • #5
          Novi Schematic
          Note: They show a #60 jet in the return restrictor this has been changed to 105-110 per Tim at Novi.
          Attached Files
          "Insanity is doing the same thing over and over again, and expecting different results"

          http://www.pwc-performance.com/
          Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

          Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

          http://www.hydrotoys.com/gpr/tuners/osidebil/

          01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
          01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
          02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
          99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

          Comment


          • #6
            Older style 1100 carbs, return to tank nipple on carbs
            Attached Files
            "Insanity is doing the same thing over and over again, and expecting different results"

            http://www.pwc-performance.com/
            Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

            Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

            http://www.hydrotoys.com/gpr/tuners/osidebil/

            01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
            01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
            02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
            99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

            Comment


            • #7
              I??m a little confused or maybe i??m not reading well , but is drilling needed for a GPR or can i only use the inline restrictor ?

              Comment


              • #8
                no need for the inline restrictor unless you drill.
                "Insanity is doing the same thing over and over again, and expecting different results"

                http://www.pwc-performance.com/
                Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

                Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

                http://www.hydrotoys.com/gpr/tuners/osidebil/

                01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
                01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
                02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
                99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

                Comment


                • #9
                  Thanks ,now it makes sence ,i thought that that a inline restrictor replaces the drilling mod ,ill go for drilling with a 95 main jet.

                  Comment


                  • #10
                    One last question to be sure before i start drilling, do i need to drill each orifice hole on each carb ?

                    Thanks,

                    Comment


                    • #11
                      yes
                      1997 Yahama GP1200- 61.7 mph(GPS)


                      Comment


                      • #12
                        Thanks, all in need to know (better safe than sorry).

                        Comment


                        • #13
                          Re: Carburetor Drilled Return Pressure Balancing Modification GPR, XLT, GP, SUV, etc.

                          Great write up. I assume this is something useful for all ski's even if they are stock correct?

                          Comment


                          • #14
                            Re: Carburetor Drilled Return Pressure Balancing Modification GPR, XLT, GP, SUV, etc.

                            I do this to all the Yami triples I work on stock or not
                            "Insanity is doing the same thing over and over again, and expecting different results"

                            http://www.pwc-performance.com/
                            Support The Forum and Save 10% off on RIVA and R&D products, coupon code is greenhulk

                            Porting by Lowell Horning "2-Stroke Porting.com" http://www.2-stroke-porting.com/

                            http://www.hydrotoys.com/gpr/tuners/osidebil/

                            01 SUV-1.8L SHO Conversion (Alex's Ski) Build has begun http://www.greenhulk.net/showthread.php?t=172812
                            01 GPR 1300 Ported BB (77.1 @7100) (Sold Cuda67)
                            02 GPR 1440 Stroked and Ported by 2-Stroke-Porting.com, Factory Triple Pipe project (Under Construction)
                            99 GP1200 Ported by West Coast Porting, Bored 1mm over, Secret Mods Motor Broke in, tuning in process. This thing pulls hard with a 14/20 J prop.

                            Comment


                            • #15
                              The carbs in the picture shown are out of a gp1200r right? If so will the tee handle fit a gp1200, i think theyre the same carb other than the acc pump? Dumb question but just wondering. Also if the line on a gp1200 is smaller can you tap the return line for a 105 pilot jet instead of a main or is it just to small?

                              Comment

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