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Old 01-06-2008, 04:26 PM
1996Fatboy's Avatar
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Location: Pennsylvania
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Default Rebuild problem

Rebuilt (or tried to) my carb yesterday. This thing was so gummed up even the drain wouldn't operate. My HD manual specifically states not to use a 3-sided fuel valve, only use 4-sided which mine did have but my kit did not. Some of the o-rings were wrong also, so either I have the wrong kit or it's universal (came with 2 styles of bowl gaskets). Anyhow, I cleaned it up while it was open checked the jets and closed it back up using one of the new gaskets (o-rings), old one tore. Now it won't idle unless I back out the mixture screw 5 or so turns. Runs smoothly with the enrichener pulled but as soon as I drop it all hell breaks loose. Tried starting at zero with the mixture, idle settings, cable adjustments, etc. All I can think of is I did more harm than good while cleaning it. Also, I backed the mixture screw the whole way out and found a small washer that was crushed. Did this after all the problems. Any ideas?

96
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Old 01-06-2008, 07:27 PM
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Didn't you just add some pipes are mufflers? Maybe it's okay, just running lean. Has anyone jetted the carb? What number low speed jet do you have? A 42 is too small for stage one use (high flow air cleaner and pipes). I figure you may have seen the number, or already know what it is.

Actually, check for this first. You might have a vacuum leak. Has anyone ever replaced intake seals? They may have become cracked if they're old, then the mainfiold got jostled when ya removed the carb. The bolts also may have come loose.

To check for leaks, engine running, you can spray the area where the manifold meets the head with carb cleaner. Another spot to watch... where the carb meets the mainfold...I've folded this gasket over a couple times puttin the carb back on.

Becareful spraying carb cleaner/ engine running; watch what you are doin. Justa little...you'll hear a rise in engine rpm when ya find the area of the leak. Sounds simple, sometimes it's not, cuz it'll also raise the rpm if it gets sucked up thru the air cleaner.

Take care, let us know what you find.
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Old 01-06-2008, 08:17 PM
1996Fatboy's Avatar
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Hi 94, Yes I did add pipes but I was running other after market pipes before. Also, these pipes were on for a couple of weeks with no problems. It wasn't until I removed the carb and cleaned the bowl that the problem occured. My main jet is a 175-I'm not sure about the low speed. I could not make out the # on it. I'll try the intake suggestions tomorrow and let you know. Thanks for the speedy response.

96
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Old 01-06-2008, 09:50 PM
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Hey, you are welcome. Gonna be nice enuff to ride to work, so figured you may fix it in time.
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