Swapped jets, and choke literally chokes the bike now. :(

[Wrightboy]

So I got a jet kit from the one and only. Just switched them out a few minutes ago, pulled the brass plugs and gave the idle mix screws 3 full turns out (after putting them all the way in of course). Fired it up, sounded terrible, bike was insanely shakey. Noticed the choke was on, I shut it off the bike roars up to 5k RPMs and sits there. My first thought was somehow the choke thing got flipped, but that's just ridiculous.

So with the choke off I used the big white middle idle thing (not sure what to call it to separate it from the ones under the caps) and adjusted the bike down to the usual 1600-1800 idle. Seems to be totally fine, but now with it set that low, as soon as you even bump the choke the bike will die. I re-examined everything plunger comes out when it's pulled...it just dies? If you hold the throttle open and open up the choke you it'll behave fine, but as soon as you drop the throttle it just goes all the way down and dies.

On a side note, for how cold it was out today it did amazing even without choke...but with the colder months coming I would really like to not have to stand there holding the throttle while it warms.

Any ideas what I messed up?

-Wright

[mitch79]

I had nothing like that happen when I changed jets to 22.5/65/147.5
Choke works as it should. Idle required minor adjustment only.

I'm not sure what jets are used in the choke circuit, but it is possible to mix up the mid and main jets which would make it sopping rich at anything above idle.

[Wrightboy]

You list three there...These are '04 carbs but in the kit buddah sent there was only 4 jets.



(Ignore the text about the o-ring, just a good picture.)

He sent two of each, numbers 26, 27.

Seriously all I did was remove the tank, unscrew the clamps, flip the carbs over, swapped what he had given me then put it all back.

I wonder if he sent me the wrong kit? (Took almost...geez...2 months? To get it in the first place)

-Wright

[Dr.McNinja]

Bunch of things to check


- First and foremost: make sure you installed the jets correctly. It's really easy to screw the wrong jet into the wrong hole (I forget which are common, mid and main maybe?).

- Second: The choke could be flooding the bike. This would have to do with jetting once again. Your bike sounds like it is REALLY rich.

[sveach]

Bunch of things to check


- First and foremost: make sure you installed the jets correctly. It's really easy to screw the wrong jet into the wrong hole (I forget which are common, mid and main maybe?).

- Second: The choke could be flooding the bike. This would have to do with jetting once again. Your bike sounds like it is REALLY rich.

Mid and main can be swapped, pilot is a different size. So you have that correct.

Wrightboy - if you have 2004 carbs, then you have 3 circuit carbs. Pilot, Mid Main, and Main. If Buddha sent you 4 jets, then he sent you a kit for the older, 2 circuit carbs (these have Pilot, and Main). So, you either have upgraded the Pilot and Main, or Pilot and Mid Main. If you upgraded the mains, you're OK. If you upgraded the Mid Mains, you're going to be running EXTREMELY rich, but not at idle. You need to ask Buddha to send you a set of Mid Main jets. Pull your carbs back off and see which circuit it was that you upgraded. I'm guessing that you upgraded the Mid Mains. Put the stock Mid Mains back in, move the new jets to the Mains, and see how it runs then.

[tialloydragon]

Try 2.5 turns on the idle mixture screws.  That should lean out the mixture a bit.

Maybe a stuck float?

How was the bike running before the rejet?

[JDezle21]

Did you PM Buddha? Seems like the most logical place to start if you ask me.

[The Buddha]

OK wrightboy - it ran great without choke, and choke chokes it ... You sure you installed the choke cable and plungers back right ? If you have not installed choke wrong and assuming it is closing fully when closed, you are too rich ... you could be fine through winter ... if needed in winter just open choke, you will ahve problems starting up in summer. Cos you cant further close a closed choke. If you are sure you dont have anything mis fitted ... like putting mains in place of mids ... then you could be looking @ an air screw set open too far, a clogged air jet, or a float going high. You're rich, no worry in winter unless chock is stuck open, of course gas milage not winthstanding. Oh, make sure air filter is clean. Also make sure you're runnign the right equipment for the kit, say you buy a kit for pipe and K&N filter, dont try it with stock filter. And dont jet it for that, it will be too rich. Cool. Buddha.

[Wrightboy]

How was the bike running before the rejet?

Honestly, perfectly...didn't really have any complaints, was just looking to maybe squeeze in an upgrade.

OK wrightboy - it ran great without choke, and choke chokes it ... You sure you installed the choke cable and plungers back right ? If you have not installed choke wrong and assuming it is closing fully when closed, you are too rich ... you could be fine through winter ... if needed in winter just open choke, you will ahve problems starting up in summer. Cos you cant further close a closed choke. If you are sure you dont have anything mis fitted ... like putting mains in place of mids ... then you could be looking @ an air screw set open too far, a clogged air jet, or a float going high. You're rich, no worry in winter unless chock is stuck open, of course gas milage not winthstanding. Oh, make sure air filter is clean. Also make sure you're runnign the right equipment for the kit, say you buy a kit for pipe and K&N filter, dont try it with stock filter. And dont jet it for that, it will be too rich. Cool. Buddha.

Hm, I didn't actually remove the cable/plunger...I just undid the clamps and flipped the carbs over everything still attached. With the tank where the seat should be I can reach in, and just light touch choke fixture to slide the plunger out the tiniest bit, and it just dies out. You guys keep saying that there's a possibility of misfitting...I kinda think I'm totally missing something here? (Definitely ignorant on all things carbs, I just look at the diagrams and follow them to the letter). With the carbs flipped, I took off the bowls...I unscrewed the two tiny jets, replaced them with the tiny ones from the kit. Then unscrewed the long ones...replaced the the long ones. I have the old ones in front of me and there's no way you can mix them, the thread sizes are like crazy different. While I had access I did re-oil the air filter (and crank case breather)...but that's about it. I guess I might play with the air screws and see if I can't make the choke at least somewhat functional.

Also, buddha, anything about sveach's comment about the '04 carbs being 3 circuit? Is that kit still only supposed to have 4 jets?

Appreciate it guys!
-Wright

[gs500e]

(Someone please confirm that is correct... i think it is correct)

[Wrightboy]

Hey great pic, thanks! The ones included, according to your picture, were the mid and pilot. Guess I'll try just swapping the old ones back this weekend just to make sure that it really is these jets causing the problem and nothing else was messed up.

[lanesplitter]

Hopefully you didn't get too much oil on the filter.  That could cause a rich condition as the filter wouldn't be able to flow enough air.

[The Buddha]

Hey great pic, thanks! The ones included, according to your picture, were the mid and pilot. Guess I'll try just swapping the old ones back this weekend just to make sure that it really is these jets causing the problem and nothing else was messed up.

Hell no ... no you did not ... grrrrr I wish I had a penny for every ... OK never mind ... here it is ...

My kit has mains and pilots only. You are supposed to leave the mids alone.
You took out a 60 - mid and put in a 132.5 ... you're drowning the poor guy ...
You were supposed to put the 132.5 where the 130 used to be.

So I guess the long one = pilot, you're good there.
The other ones you took out need to go back where they came from.
Then the ones I sent you need to go where the third jet is.

The carbs from 89-00 really have more than 2 circuits too, more like 4, air screw, pilots, needles and mains in that order.
The 04+ carbs have the same 4 plus a mid that overlaps with the needles. Shimming the needle (the O rings I send in the kit sorry no washers - or you can put the washers out of the top of the e clip into the part under the e clip on the needle) works to do the same as the mid increase and is a whole lot cheaper.

So you put the right mids back, remove the mains and put the mains in there. Oh, if you're working wiht the cables still conencted, make sure they dont kink if they do you again will be wondering about the choke. Also the mids on this bike want to come off the carb with teh emulsion tubes. You may want to put a crescent wrench on them to keep em in place and unscrew the mains.

Cool.
Buddha.

[Wrightboy]

Hey great pic, thanks! The ones included, according to your picture, were the mid and pilot. Guess I'll try just swapping the old ones back this weekend just to make sure that it really is these jets causing the problem and nothing else was messed up.

Hell no ... no you did not ... grrrrr I wish I had a penny for every ... OK never mind ... here it is ...

My kit has mains and pilots only. You are supposed to leave the mids alone.
You took out a 60 - mid and put in a 132.5 ... you're drowning the poor guy ...
You were supposed to put the 132.5 where the 130 used to be.

So I guess the long one = pilot, you're good there.
The other ones you took out need to go back where they came from.
Then the ones I sent you need to go where the third jet is.

The carbs from 89-00 really have more than 2 circuits too, more like 4, air screw, pilots, needles and mains in that order.
The 04+ carbs have the same 4 plus a mid that overlaps with the needles. Shimming the needle (the O rings I send in the kit sorry no washers - or you can put the washers out of the top of the e clip into the part under the e clip on the needle) works to do the same as the mid increase and is a whole lot cheaper.

So you put the right mids back, remove the mains and put the mains in there. Oh, if you're working wiht the cables still conencted, make sure they dont kink if they do you again will be wondering about the choke. Also the mids on this bike want to come off the carb with teh emulsion tubes. You may want to put a crescent wrench on them to keep em in place and unscrew the mains.

Cool.
Buddha.

Buddha...my brain just exploded.

I was still not seeing it. I was like Wth are you talking about, the main is FRIGGIN HUGE in that picture, how is that supposed to work?! ...and then I looked closer...I'm going to go hide under a rock and take my shame and embarrassment with me lol. So...what I think I'm seeing...and I assume this is what I was missing...the top unscrews off the...whatever holds in the emulsion tubes?. Your crescent wrench comment is what really confused me for a second. How the heck did I strip down and clean the carbs and not notice the big one had a jet on top! 

But I see it now! So...unless I'm still off. Come this weekend, I will unscrew the jet from the top of whatever you want to call that large thing in the middle, and put the old mids back where they belong.

Thanks for putting up with me guys. 
-Wright

[NickyNumbers]

You aren't the first one to do that and you certainly wont be the last.


After breaking down the carbs a few times, you'll be an expert.   Good luck

[gs500e]

Buddha...my brain just exploded.

I was still not seeing it. I was like Wth are you talking about, the main is FRIGGIN HUGE in that picture, how is that supposed to work?! ...and then I looked closer...I'm going to go hide under a rock and take my shame and embarrassment with me lol. So...what I think I'm seeing...and I assume this is what I was missing...the top unscrews off the...whatever holds in the emulsion tubes?. Your crescent wrench comment is what really confused me for a second. How the heck did I strip down and clean the carbs and not notice the big one had a jet on top! 

But I see it now! So...unless I'm still off. Come this weekend, I will unscrew the jet from the top of whatever you want to call that large thing in the middle, and put the old mids back where they belong.

Thanks for putting up with me guys. 
-Wright

You're definitely not the first to do that.
I did it about 6 months back (I realized i had done it after putting on one carb bowl, before putting on the secod one).  That is why i decided to make that picture.
Heck... you'll see that the post of that pic was edited... that's because i labeled them incorrectly the first time.
(And no, my carbs aren't that clean... that's a pic i stole off the internet some place.)