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  #1  
Old 3 Weeks Ago
JSH JSH is offline
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Default 1980 XLH Carb Problem!

Help?
A couple of weeks ago, a guy brought me this almost pristine 1980 model that had been sitting in his living room for about 12 years. He wanted it running so he could sell it. I did all the usual stuff - installed a carb kit, checked the float for buoyancy and holes, changed fluids and spark plugs, fixed electrical issues, all a result of sitting too long. The entire tank and intake system was shellacked about 1/8th inch deep in semi-solid tar-like fuel residue. That took a days cleaning itself. I was ultra-careful with everything because the bike was so perfect for it's age. Most of the covers and parts had obviously never been removed since the factory assembled it. First turn of the throttle fired it up and it runs beautifully - except the carb overflow poured gas whenever the petcock was turned on.
I pulled the carb again and checked float needle and seat. It was in correct adjustment and sealed easily when the float was gently lifted. I checked for a leak in the bowl overflow tube - perfect seal, even under air pressure. I tried a different but new needle, which also seemed to seal nicely, but when reassembled, the overflow poured again. I am confounded and am wondering what the problem could possibly be.
It has a stock HD carb, seems to be a keihin, but I cannot find what model it is. The only number I can read on it seems to be "B83DRH08." I am thinking of replacing the float, needle, and the whole bowl, just because I don't know what else to do, but cannot find those parts anywhere for this particular bike.
The owner wants it left as stock as possible, and I don't blame him. Any thoughts or tricks you may have are appreciated.

https://lh3.googleusercontent.com/aq...60-h960-n-o-v1

https://lh3.googleusercontent.com/7j...60-h960-n-o-v1

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Old 3 Weeks Ago
Iron Mike Iron Mike is offline
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Default

Don’t recall on the K butterfly carbs, but what seals the needle seat in the carb body? O-ring?
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Default

does the float swing easily on it's "axle"? maybe it's getting hung up on it's way to closing off the inlet? try flipping on the gas valve and when it over flows tap on the bowl with a screw driver handle or similar and see it stops it.
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tedcool tedcool is offline
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Default

I just rebuilt my Keihin butterfly carb last week. No issues, thankfully!

The seat for the needle is just the casting I think - no O ring.

'Sportster Paul' has some YouTube videos about rebuilding this carb. Those were useful.

His advice was to clean the seat by using the end of a sharpened pencil and gently twisting it on the seat. Just the soft tapered wood of the pencil to wipe whatever crud might be there.

I was careful to get the tiny wire that attaches the needle to the float sitting in a 'happy' spot.

I used the needle with the spring loaded pin. My rebuild kit came with both. You have to use the 'measure holding the carb sideways' technique to set the float height correctly if you use that one.

Paul also showed how the pin on the end of the needle can wear a pit in the arm of the float. That will make the float hang up. You have to carefully file / sand / grind the float arm to smooth it out as best you can, or else replace the float if you can find one.

Good luck!
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That is the correct number for a 80 Sportster Keihin carb.
27469-80A (B83D)
Here is the main IH carb page with sub page links.
http://sportsterpedia.com/doku.php/t...late_1976-1987
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The float needle seat is just the plastic bushing/housing the needle slides in, and is pressed into the carb body casting. There is no rubber seat that I am aware of. The tip of the needle itself is rubber.
The float swings silky smooth and easy on it's hinge pin. After reinstalling the bowl, I tipped the carb upside down and shook it gently a few times. You can hear the float easily moving up and down each time. I also blew into the gas fitting as I tipped the carb up and down - it opened and closed perfectly until I was red in the face from checking it. I tried the screwdriver trick too, once it was running, with no success - But I don't think the float is binding. It just seems to work so perfectly when off the bike.
There are two small hole in the bottom of the bowl together near it's bottom edge. I cannot remember what they are, possibly to do with actuating the accelerator pump. I cannot imagine how, but could they have anything to do with the problem?
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Default

You're right - the two holes inside the bottom of the bowl are for the AP.

If the AP cover isn't on right or you messed up the tiny O ring, it could leak there.

Are you sure it's coming out the overflow?
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Here is a piece on troubleshooting the overflow.
http://sportsterpedia.com/doku.php/t...#fuel_overflow
If the standpipe is corroded in the middle somewhere or at the bottom, it'll leak.

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Iron Mike Iron Mike is offline
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I was thinking fuel could be passing around that needle seat, between the insert and the carb body.
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Iron Mike Iron Mike is offline
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Is the overflow tube Hippy pointed out cracked?
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