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Carb trouble

Discussion in 'CVP Stage 1 Tuners Kit' started by Sport1200, Feb 15, 2010.

  1. Sport1200

    Sport1200 New Member

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    Hello,
    I'm new to this site and could use some help with my bike. I have a 2005 Sportster 1200 XL Roadster. I've installed the stage one kit along with an Arlen Ness Big Sucker air cleaner and 2-to-1 Thunderheader exhaust. I've winterized my bike and in the process removed the carberator to install new intake manifold seals and a carberator gasket. While I had the carb off I also dissassemble it and cleaned it out. I've now rebuilt it (with the help of a Clymer's owner's manual). I have a 180 main jet, 45 slow jet in the carb that came with the kit. I have reisntalled everything and torqued it all down to spec. I started the bike and it sounds great. I have a problem, however. The bike idles fine but when I try to roll on the throttle the bike will stutter then stall out as if it is not getting any gas. I can give the throttle a quick twist and the bike revs up but trying to twist slow and easy will stall the bike. Any suggestions on what the problem might be? Thanks
    -Sport1200
    Sport1200, Feb 15, 2010
    #1
  3. chucktx

    chucktx Moderator Staff Member

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    check the accelerator pump....it sound like it may be leaking when you slow roll the throttle, but when ya quick twist, the small leak doesnt affect it....
    chucktx, Feb 15, 2010
    #2
  4. Sport1200

    Sport1200 New Member

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    How do I check for a leak? I've taken the carb off with gas still in the float bowl and when I turn the throttle plate quickly I can hear and see the gas come out but when I do it slowly there is no indication of any gas.
    Sport1200, Feb 26, 2010
    #3
  5. cowboy

    cowboy Moderator Staff Member

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    you have a 05, you have to let it idel to see ,that carb has a vacume line on it
    cowboy, Mar 1, 2010
    #4
  6. kenfuzed

    kenfuzed Administrator Staff Member

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    A couple things to check out.

    1) You mentioned installing new intake manifold seals and carb mount gasket. There have been reports of service manuals having the flange's and gaskets backward, so make sure they are installed correctly. Also I have seen quite a few faulty manifold seals (the donut boot) that are very loose. The carb spigot should press onto this seal very tight and not be so loose that it can fall off the manifold.

    2) Check your float level. If the float tab bent while assembling the carb could be starving for fuel. A quick twist of the throttle supplies a blast of fuel from the accelerator pump whereas a slow acceleration won't deliver enough fuel if the bowl level is low.
    kenfuzed, Mar 1, 2010
    #5
  7. Sport1200

    Sport1200 New Member

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    The float level, gaskets and boot are all fine. I've taken the float bowl off with gas in it (and there seems to be plenty) and pressed the accelerator pump. There is the normal squirt of gas from the fitted brass injector but there is also gas squirting up from a small hole in the bottom of the float bowl. Is that normal, it looks like the hole is manufactured to be there.
    Sport1200, Mar 8, 2010
    #6
  8. kenfuzed

    kenfuzed Administrator Staff Member

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    Yes the small fountain-like squirt inside the bowl is normal and doesn't happen to that extent once mounted.

    Perhaps the needle jet (chrome looking nozzle) is mounted upside down. This is the silver bushing piece that fits above the emulsion tube and protrudes into the carb throat. The needle tip moves up/down inside this piece and it should have the larger open end facing up toward the slide.

    In the picture below the needle jet is labeled as the colar.
    [​IMG]
    kenfuzed, Mar 8, 2010
    #7
  9. YeahRight

    YeahRight New Member

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    Hey there Ken - excellent pic and decscription on what I was looking for. I just had the "bleed needle - main jet" out of mine. All back together now. I only changed the slow jet from a 42 to 45... fyi. In the meantime the collar fell out when I had the main jet assembly off. I put it back together but I'm not sure if I got the collar in correctly. I assumed that it can only go one way??? So I think that you are saying that if it is upside down, the symtom would be as Sport1200 describes it?
    Thanks.
    YeahRight, Mar 11, 2010
    #8
  10. kenfuzed

    kenfuzed Administrator Staff Member

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    It is possible to put the needle jet (collar, nozzle) in upside down. On one end it has a small hole and the other end has a larger funnel-shaped opening. You want the larger opening facing up into the carb throat and the smaller end mated against the emulsion tube. Having this piece correctly oriented is imperative to the carb operating correctly.
    kenfuzed, Mar 11, 2010
    #9
  11. YeahRight

    YeahRight New Member

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    hmm well - I'm trying to decide whether to take it apart and make sure. I'm kinda anal that way However, there was no stalling or popping, coughing when I rode it last night for about (10) miles. Do you agree, must be okay?

    Sport1200, how did you make out?
    YeahRight, Mar 11, 2010
    #10
  12. Sport1200

    Sport1200 New Member

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    Well, now I feel like an idiot. Apparently, when I took the carb apart to clean it I must have lost the needle jet because it wasn't in the carb at all. I went down to the local HD shop and got one for about 10 bucks and it now runs great. Thanks for all your help.
    Sport1200, Mar 11, 2010
    #11
  13. kenfuzed

    kenfuzed Administrator Staff Member

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    Don't feel bad, this is very common so I probably need to highlight this better in the instructions.
    kenfuzed, Mar 11, 2010
    #12
  14. YeahRight

    YeahRight New Member

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    That's good news Sport1200. Me on the other hand, took it back apart to make sure I had the needle jet in correctly. Guess what? I did. 50-50 chance right, HA.
    YeahRight, Mar 12, 2010
    #13
  15. sarge7

    sarge7 New Member

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    Sport 1200 - Glad ya got it fiqiured out - and all working good. Been there and done stuff like that a few times myself; but it's a learning experience that I'll bet you don't repeat next time.
    In any event enjoy the ride - with spring just around the corner haveing a ride thats not up and running is a real PITA.:)
    sarge7, Mar 13, 2010
    #14

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