At my ends wits! Won't stay running without full choke!

I have tried everything I can think of or that I have read to check. The bike will not stay running without the choke fully out. Please help! Any advise before I have to pay someone to fix it?

I have a 1989 Sportster 1200 conversion. hypercharger air filter, straight pipes. I soaked carb for four hours, new seals all the way around, new accelerator pump diaphragm. Brand new slide (beacuse the old had been drilled out). I rejetted with deluxe stage 1 kit (jets #45 idle & # 180 main), mixture screw is currently sitting at 2 screws. I have tried the propane test around intake and exhaust (no change). I don't think I have a vacuum leak but I'm not 100% sure how to check, the lines from VOES are not cracked nor is the tee, one line going to top of carb the other to the hypercharger. Not sure where to go from here.

I've experienced that exact problem with a few small single carb engines. Soaking the carb may not be enough. A micro passage could be plugged and the solvent won't get to it or remove it. I had to replace the carbs on the engines I had that choke to run problem. It was from the gas sitting in them. I am not familar with HD carbs but dollars to donuts, a new or rebuilt carb will fix your problem.

try spraying carb cleaner into all the little holes in the carb, make sure you didn't pinch the rubber boot at top of slide, make sure accelerator pump rod is in correctly and that it is working. fuel line could be plugged, I'm not familiar with the hyper cleaner so don't know if the voes connects to that or not. good luck !!

Thanks for the advice, I probably should have stated in my original post. I did inspect and clean all of the passage ways after I soaked the carb. What else might I have missed?

Did you take the carb apart to soak it?? Could be a plugged pilot jet...gotta make sure you can see daylight through every hole in the jet and there's nothing in them....

Yes I did take the carb apart, the emulsion tube and jets are all new.

KK...did you check float level height??if it's sitting too low you won't pull up any fuel...

Here's some trouble shooting steps...

http://bike-talk.com/forum/cv-performance/17202-faq-carburetor-tuning-issues.html

You needed a torch tip cleaner, a new seat, new needle valve. Gaskets and a can of carb cleaner. You should of took the carb apart on a table, and sprayed the carb good,
Then checked all passage holes spraying threw them and making sure the carb cleaner went threw the holes. Then take the torch tip cleaner and put it threw all the holes.
Install the new seat, And when you put the float on with the needle jet. DO NOT bend the float jamming the needle jet in the seat to damage the needle.
The float levels should be checked. And new gaskets putting it back together.
You should of blown in the hole with your mouth on the carb and seen if air went threw. Then turned it upside down and see if no air went threw the carb.
If all that checked out. You should of taken the petcock off the gas tank and checked the screen on it and made sure gas was coming threw it good.
A bike that old can get trash and rust in the gas tank causing problems.
If you didn't check the petcock and all you could of put more trash right back in the carb.
And I would of replaced the fuel line hoses. The Ethanol is eating the holes up putting the debris back into the system. They say to replace the hoses every 3 yrs. You can't see the ethanol eating the rubber off the inside of the hose unless it gets caught in a filter.
When you get it fixed put some Starbrite Startron in the fuel to help with the ethanol.

Thanks for all of the replies. Last night I pulled the carb back off, did another cleaning just incase I missed something the first time (payed special attention to all the small passagees). I also checked float level and replaced all the vacum lines just to be safe. When I get sometime this week I will pull the petcock and cahnge out the fuel line. I will post my findings this weekend.

Check the screen on the petcock

and run a little seafoam in the tank never hurts.

+1 on that.

Not seaform, Starbrite Startron.

Nuttin' wrong with Seafoam,or Marvel Mystery Oil,they all do the same thing as Starbrite Startron

We tried it all in 2 stroke carbed boat motors. You are gonna get the biggest problems with 2 stroke carb boat motors giving you crankin and running problems. I live on the 2nd largest lake in Texas.
Worked for The Boat Doctor for 4 yrs. We worked on outboard and inboard motors, not to mention me helping other buddy's with their bikes.
And we have ran it in Harley Motorcycles.
What you are trying to treat is the ethanol and the stabilization of the gas. And to help get rid of water.
Startron will do a better job . And stabilize fuel longer.

But you use whatever you want.

Exactly All 3 do the same thing... Startron Might be a little better...Do you have any comparisons to show it really is??

Uh oh ! ?

:roflmao::devil: