I just had my Carburetor rebuilt and now my bike is bogging out

[Popeye_5591]

I recently bought a 1999 road star 1600. When I took the bike off the road this year I sent the carburetor out to be cleaned and rebuilt. I just got it back and installed it and I cant get it right. here is what happened

1) I installed the crab and when I went to start the bike the crab pissed fuel every where (From the jets, not the fuel line) and then backfired which started a fire on the side of the bike. I was able to quickly put the fire out. The only damage was the plastic cover on the diaphragm melted and the spring blew through it. I replaced that part already.

Edit: It melted the decel diaphragm cover on the side of the Carbonator, fortunately no other damage.

2) The shop that rebuilt the carb said that I should check the pressure of the fuel coming from the pump, which I did. it measured 4.3 PSI. The shop told me that this was my issue cause the pump should be putting out 1.7 PSI. (Is the PSI really supposed to be 1.7 ?)

Edit: As per the manual the fuel pump pressure spec is 2.2 psi to 2.9 psi. My pressure was actually correct, I was not measuring it correctly.

3) I decided to removed the fuel pump and went pumpless which is currently the way the bike is set up. I did not change anything besides running a fuel line from the petcock to the carb with the factory fuel filter as the inline filter for now.

Edit: I reinstalled a fuel pump system to be able to trouble shoot the carborator issue without the variable of an untested gravity fed fuel delivery system. I will 100% return to gravity fed once I get this carbonator squared away and the bike is running as it should.

4) I reinstalled the carb and there were no leak's in the carburetor. I choked the bike and it started right up and idols perfect. I closed the choke and the bike still idled great so I let it warm up.

Edit: One of the issues was that the float needle seat was leaking from around the seal. Taking out the fuel pump and going gravity fed seemed to have stopped the leaking because there was no more pressure, but it did not solve the problem. It just masked it.

5) After warm up, whenever I give it some throttle and the bike totally bogs out. when I look at the main jet it looks like its pushing way to much fuel and flooding the bike. I took apart the carb see if the initial "Fire" cause any damage and I reset the jets and needles. everything was brand new and looked good. I just reinstalled the carb "gravity fed" and still has the same issue.

Edit: The Problem was 2 fold:
1) The seal in the float needle seat wasn't changed when the carb was rebuilt. It was allowing fuel to freely go around the seat and flood the carbonator. A new seat and o ring solved this problem.
2) The accelerator pump was partially clogged. They cleared it with a very small sharpened wire. This solved the problem.

Conclusion: Carburetors are tricky. The shop that did the work on my carburetor has been around for ever and is a highly regarded shop. They work on only carburetors and are well known in the classic car and race world. And there is the issue. They didn't under stand my Japanese motorcycle carburetor. My takeaway is that if you are having a carburetor issue and cant handle it yourself, take it to someone who specifically knows Road Star Motorcycles. For me, I will use one of the guys on this site. You can ship your carburetor to them and they know what they are doing. It will be done right because they understand your bike. They are quick to give us free, solid advice on this site. I think at the very least they deserve our business. Read some posts and you will quickly see who is best to do the work. There are more than a few here that can help you.

Thanks

[Shotround]

standard response yer gonna get from the others when they get back online.....what jets are in it and how many turns on pms. what needle too. did ya take pics when you had it opened?

[Popeye_5591]

I did not take pics it opened up. I can take it apart again to answer any questions and take pics. I just need to know what info/pics you guys want to know/see

[Shotround]

theyre gonna ask about air filter and exhaust too.

[Popeye_5591]

Exhaust is cobra pipes with the baffles in. I did not have an air filter on for these tests. also Its probably important to mention that the bike was running pretty good before I sent out the carb. I wasn't having any of these issues. Also, when I had the thing apart i did confirm that the main jet was 165.

Not sure if these pics of the jet will help

[Shores]

Sounds like the flooding was caused by your floating stuck. Most shops don't know what they're doing on these bikes. It's best to consult folks here and do your own work.

[Father Pobasturd]

When going pumpless, did you change the float needle and seat to a Yamaha Grizzly set-up? This is recommended, but not always necessary. Also, there's a small filter behind the metal inlet tube on the carburetor. That filter needs to come out. That tube is a compliance fit. I would also remove the factory filter you are using as an in-line filter. See what it does after that. I have the Grizzly valve and no filters, been running it that way 6 years now with no issues. Many guys run an aftermarket in-line filter. Also, try to keep your fuel line routing high as possible without creating an "uphill" situation.

PS. Before trying to run it through some "Recommended Shops" or "Authorized Yahama Dealers", try getting someone here to walk you through it. If you managed to re-install the carb on your own, you must have at least a minimum of mechanical prowess. That's enough for what you are doing. You wouldn't how many bikes we have seen here that came back from the shop worse than when they went in. Ask questions, yea, we have heard them all, probably a million times or so, but if you don't know your nomenclature, the search engine won't help you much.

[Popeye_5591]

Thanks pobastard. I haven't done any of that stuff yet. I only went pumpless cause i was told my pump was putting out to much pressure at 4.3 psi. I wanted to take it out of the equation, but the bike seems like it's flooding now. I don't know if it's the pump change or something this guy's did to my carb. There are to many variables right now and I don't knowbhow to start troubleshooting it all.

1) rebuilt carb that worked fine before i sent it out.ii don't know if he did something to cause this

2) the guy said to remove fuel pump cause it was putting out to much psi. So now I'm running no pump.

Don't know if the issue is the carb or the pump.

BTW, i do like the look of pumpless and i will keep it that way once i rule that out as being the problem

[Shores]

After a decade of being on this form I have never heard of an issue where a pump puts out too much pressure. The guy's gas lighting you!

[Duke]

It sounds like a auto fuel pump to me, at 4.3 psi, and could be enough pressure to overcome the needle/float setting.?.?.
I've seen auto fuel pumps that looks a lot like RS fuel pumps.

[Popeye_5591]

The guy who I bought the bike from told me he put a new fuel pump in. upon inspection It has zero markings on it so i don't know what kind or type it is. I know its putting out over 4 PSI cause I put a guadge on it. I'm sure it was a $20 Chinese piece he got on ebay or amazon. Either way it is now out of the equation and I am gravity fed and hope to stay that way.

[Duke]

4.3 psi is to much pressure, and 1.7 psi is about right. I believe that RS pumps are rated at 2 psi.
You said that the main jet is a 165, "which is a stock jet", and should be a 167.5 if running the Cobra pipes and a better air box. You should also be running a adjustable needle and set on the 4th notch down from the top.
When you pullthe bowl off the carb, I need a picture of the small starter jet, to see if it's a blank jet or need to be a numbered jet. Some early 1999 carbs use a # 575 starter jet, and later RS use a blank (no hole) jet.
The picture of fuel coming out of the jet tube, "emulsion tube", alongside the needle is normal when twisting the throttle open. You should be seeing a spurt of fuel coming out of the exceleratior pump tube when twisting the throttle too.
When you say it bogs out, try pulling the choke out and see if it bogs out "more or less" and let us know what it does.

[Popeye_5591]

Thanks Duke. I removed the needle you are speaking of and its not adjustable. there is a cirque clip but only one notch where it is currently sat (See post below for pic). I will open her back up tonight or tomorrow and get you the info you ask for.

[Duke]

One notch on the needle tells me it is a stock needle. You will need a performance needle to dial in your carb if your not running a stock Air Box.

[Popeye_5591]

I am running a stock air box

[Shotround]

leaking oring at float needle seat? maybe they bumped the float tang. check float level.

[Shotround]

1) I installed the crab and when I went to start the bike the crab pissed fuel every where (From the jets, not the fuel line) and then backfired which started a fire on the side of the bike. I was able to quickly put the fire out. The only damage was the plastic cover on the diaphragm melted and the spring blew through it. I replaced that part already.

black plastic cover on top of the carb? did you inspect diaphragm for holes? did you take photo of needle in the slide?

[Popeye_5591]

No Shotround, Not That Diaphragm. It blew out the cover of the small one on the side. I did inspect both bladders though, and they are in tact. I will send photos of the needle you are requesting tonight or tomorrow when I get it apart again.

[davej]

take Dukes advice but also install the air cleaner to get an accurate feel for how the bike is running. The bike will run like shit without the air filter installed.

[brianmac]

id rather bring my RS carb to a olr skool HD mechanic than a JAP bike mechanic. these young pups dont know one end from dother. BTW, anybody near me by Cape Canaveral needs carb help, bring it on

[Popeye_5591]

You should also be running a adjustable needle and set on the 4th notch down from the top.

Here is a pic of the needle. It is not adjustable

[Shotround]

any chance they got the pms screw, spring, washer and oring in the wrong order? better yet, did they really clean it out? i had that bog a time or two. removed the pms and gave a squirt of carb cleaner in the opening.

did they replace the jets and orings when they rebuilt it? or was a clean and put it back together type job? it could be possible wrong jet installed or damaged orings.

[Lug Nut]

Well if the issues that you're having and having somebody already screw it up and all the past experience I have on these bikes I would tell you this much: If you want to enjoy your bike ride it and not be on here nightly talking about what you've tried and what isn't working and how things are going, send your carburetor to one of the guys on here that does work and let them fix it once and for all completely no more screwing around then you just ride your bike lol. Unless you like taking your gas tank off and taking your carburetor off Another 10 times trying to get everything just right, spend a little bit of money send your carburetor off and get it fixed correctly for what you have done to your bike.

My .02 worth

[Duke]

You are totaly correct LugNut!

[Popeye_5591]

The crazy part of this whole thing is that I did send the Carb out to a very reputable shop that only does carburetors. It cost me $230 and then another $30 to replace that diagram cover that melted. So I'm in it $260 and I'm still here trying to figure out why I cant ride my bike. I never realized that guys on this site should be the goto "shop" for things like this. Lesson learned and I will turn to here in the future. It makes sense that I come here for you guys to answer questions and your supporting me - I should reciprocate by having you guys do my work. Point Taken Lug Nut! Duke, I cant thank you enough, you have been so responsive.
I think I figured out what my issue is. I believe the slide is not lifting which is restricting the airflow and flooding the bike. I will have time to work on this tomorrow and I will report back if this is the issue.
Thanks again for all that have commented so far!

[Popeye_5591]

Problem Solved. I sent the carburetor back out to the shop. Apparently he never change the seat for the float needle and it was leaking like a (whatever leaks alot). in addition the accelerator jet was clogged AND the pump was sticking. I got the carburetor back yesterday and installed it. She fired up on the first try and without even using the choke. After letting her warm up for a bit, I took her out for an extra chilly ride around the neighborhood. Perfection!

This was an intense experience for me. This bike Im Working on is my second road star in my garage. She was a "Barn Find" and the guy pretty much gave her to me. My first Road Star is well maintained, but it goes to the shop for everything. I decided that I would fix and maintain whatever I could on the "Barn Find" bike. Its been a great learning experience so far. Some times very intimidating, but very satisfying when I've finally get the issue fixed.

The carburetor was the hardest problem I've had to solve so far. 3 months ago a literally knew zero about carburetors. Now I have to be careful cause I know just enough to get my self in trouble. lol.

Thank you to all on this forum that have given me advice. this site is an awesome resource and that's only because of you guys. The motorcycle community comradery and how we
help each other has always been a big part of why I love Motorcycles. I hope that I can help people one day like you guys help me here. Its a blessing and I thank you.

I went back to my first post and added my findings and how they were ultimately solved. I hope that helps someone.

Till Next Time...

[Lug Nut]

So you sent your carburetor to an actual carburetor shop and they didn't do all of those things that had to go back and fix? What the hell did they do for $230??

[Popeye_5591]

I never much minded paying for a job well done. However, In this case they made me pay $230 to chase my own tail for a week. I cant cry over spilled milk though lug nut. what's done is done. In the future I will do my own work even if it means messing up occasionally and eating some crow. Working on my bikes will be frustrating for me at times, but nothing beats the feeling when you get her right and take her out on the road knowing what you just did. I've always been intimidated at the thought of turning my own wrenches. That's has to change for me. I regret not diving into this rebuild myself. I'm sure I would have done a better job. BTW Brad G is 100% correct. I'm sure its running rich right now. Im gonna deal with that next week.

[Brad_G]

Popeye_5591 doesn't sound like they did a very thorough job the first time around if they missed all that. You mentioned a chilly ride and it starting without using the choke (technically called an enricher as it really works differently...but that's not a big issue).

When you get a chance to ride it more you may want to pull the plugs and see what they look like. A term "reading the plugs". My guess is that it's running rich if you can start it without the enricher. It may start and run now but still not be setup exactly as it should.

I like this "barn find" bike to learn on while you ride your other one. I recently picked up something similar. Quite neglected and I'm not going through trying to restore her back to some form of her former glory. You can learn a lot while doing that and still be able to get out and ride.

[Popeye_5591]

Yup. It's def running rich Brad. Today I started up her with no choke and she fired right up quick just like yesterday. Then i pulled the choke and it flooded and wouldn't start. I then let her sit for about an hour and once again she started right up again with no choke. I just put new spark plugs in and I'm gonna go riding sat. After that I read them and that will tell me the story even though I'm pretty sure I know what they are gonna look like. Time to learn how to tune a carb!