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The Carb Shack Rebuild Process

The Journey To Us

Getting your carbs to us is the first step. All you need to do is package them securely and send them to the address listed on our [Shipping to Us] page. On that page, you’ll also find plenty of tips and recommendations to make the process simple and stress-free, from packaging advice to courier options.

The Inspection

Once your carbs arrive, we carry out an initial inspection. This helps identify any visible damage, underlying causes of the running issues, or parts that may need replacing beyond a standard rebuild. If anything crops up that might pause the process, you’ll be updated straight away before we continue.

The Strip Down

This is where the real work begins. Every jet, screw, pin, bolt, pipe, O-ring, and washer is carefully removed until only the bare carburettor body remains. This ensures that no detail is overlooked, and every component is properly dealt with.

The Ultrasonic Deep Clean

All safe components are run through the ultrasonic cleaner using a specialist fluid that’s tough on dirt, varnish, and old fuel residue—but gentle enough to protect soft metals. This process gets into every hidden passage and ensures your carbs are completely clean inside and out.

The Rebuild

With everything spotless, the carbs are rebuilt using only high-quality kits, equal to or better than OEM standards. For those looking for performance upgrades, DynoJet kits can also be fitted for an additional premium.

The Tune-up

Before your carbs leave, they’re fine-tuned with precision:


  • Float heights are set to the manufacturer’s recommended spec.
  • Idle mixture screws are adjusted to manual settings.
  • Carbs are bench-synced accurately using feeler gauges.


This ensures they’re ready to run as smoothly as possible once back on the bike.

The Polish Up

Before packing, the carbs get a final polish to bring back that fresh, cared-for look. It’s the finishing touch that makes all the difference.

The Journey Home

Finally, your carbs are packaged securely and shipped back to you via Royal Mail 24-hour tracked service. That way, you can rest easy knowing they’ll return safe, sound, and ready to bolt back on.

This ZX6R hadn’t run in 9 years, after an ultrasonic clean and rebuild here at The Carb Shack, it fired back up and is running sweet once again ! Thank you to our customer for sharing this video, the sound of an engine breathing again never gets old. 💪

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