Join Date: Jul 2009
Location: Mechanicsburg, Pa
well, I removed the carb again and took it apart to re-do everything . I removed and checked the diaphragm for the coasting enricher and removed the main needle jet and needle, remove the pilot jet. When I held up the pilot jet to check the opening, I saw some light through it, but not much. I blasted the jet with carb cleaner, and when I looked again, it appeared that the opening was larger. So, I'm thinking that might have been still slightly clogged. Also, I put the tube from the carb cleaner down into the tower that the pilot jet was removed from, and I added some material to pack around the tube, so that it would seal the opening and force pressurized cleaner through the port and out of the openings in the venturi. I also blasted the starting enricher (choke) bore as well. A got the bike to start up and it idled well. I don't know if it is typical, but this particular carb/engine does not like to run without the air cleaner. Some of it could be the exhaust pipes that were put on it, but it seems there is too much air for the carb and it backfires the through the carb. So, I just cover half of the opening with some masking tape to meter some of the air going into the carb...
I took to bike up the street and back a couple of times and opened the air cleaner and checked for fuel. It was dry at this point. I proceeded to fully assemble everything and took it for a ride again down to the gas station to fill the tank. After I stopped to fill the tank and when I went to start the bike again, it didn't fire after a couple of cranks. So, I was thinking I had the problem back again. I checked the air cleaner and it was dry. I tried to start again and it fired up, but it was idling a little low. I had adjusted the idle when it was fairly cold, so it might have been that I had it adjusted incorrectly. The no-start problem might be from another problem with the ignition switch that happened recently, I'm not sure at this point. Tomorrow will be another day, weather permitting. All take it out again and see how it does then.
It conclusion at this point, make sure that the pilot jet port is cleared, as well as the jet itself. Also check that the petcock is not leaching gas while the bike is parked. Check by removing the main gas line. The petcock should not allow fuel to flow when in the reserve and on positions, only at purge. Mine was allowing some fuel out, so I replaced the packing and the o-ring on the vacuum diaphragm.