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Discussion Starter #1
Ok guys I’ve got a 03 800 classic I’ve rebuilt the carb but it’s still flooding after the rebuild. It has V&H drag pipes no baffles stock air box, it has 135 main and 135 secondary jet and was running but very bad. wouldn’t idle long and plugs fouling out and stumbling bad at part throttle. So I tryed puting in new Float and now it want start at all and flooding even more now. So any insight would be great. Bike only has 8500 miles it sat for about 5 years.
 

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Starting at the top of the bike:

1. The petcock should not release gas without the engine running on the "on" or "res" setting, on "pri" it will free flow gas. If yours is letting gas through on "on" or "res" there is an issue. Clean, rebuild, or replace the petcock. Check the tank for sediment, clean if necessary.

2. Clean the carb. Use compressed air on all the jets and passages. After you're 100% sure it's clean, clean it again.

3. Check the float needle for damage or crud, needle seat for damage or crud, and float height.

4. Confirm that the jets are the correct size. Keep in mind that the PO may have drilled them out. The stock jet size will be fine for a stock airbox with aftermarket exhaust. The slide needle isn't adjustable, but check that there aren't any washers, etc. in there. Confirm the idle screw is set to factory setting.

Start there and check back if you're still having an issue. The carb shouldn't be flooding if your petcock and float and float needle are working properly.
 

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Flooding is a sign the float and or seat is not working.
Check that the float DOES float, and that if you shake it there's nothing getting inside it.
You can also check the if the float and seat work before you install the carbs back on the bike.
If that all checks fine, then you might have an enlarged jet that just isnt the right size.
 

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what year is your 800? over time that rubber vacuum line that runs from carb to petcock can start to crack, it might need replacing with a new hose, also check your fuel line hose, that also can develop dry rot cracks
 

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Discussion Starter #6
Yeah I got it fixed with a petcock rebuild but the problem later came back so I replaced the petcock and now it runs perfect.
 

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Thanks for the reply. In my case the petcock seems fine.

I have just updated another forum post. My carb was missing the needle jet. The piece the needle goes into.
 
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