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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #1  
Old 11th September 2012
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Default 95 CV carb problems

Ok so here's my current situation, I have my 1995 Sportster 883 Hugger, it has a jetted carb (did it too many years ago to remember what all I did and was learning from my step dad at that) Tried starting it to no avail, shop told me it was probably dirty. I haven't ridden it in a couple of years, the shop took it to told me he'd have to charge me at least $152 for him to do a carb clean, so I told him I'd give it a shot myself first. I followed the Factory Service manual step by step and disassembled the carb cleaned it all out and put it back on the bike (everything inside looked serviceable) I was given new jets to install but didn't due to the fact the bike ran perfectly fine before sitting and I thought that I had the right jets already installed. It will start and run now with the choke all the way out and continue running up until 1/4 choke, after choke all the way it it will die. I've turned the ideal screw in from 2 1/2 turns out from seated and it will idle up with 1/4 choke but still always die with choke all the way in. If you try to give it throttle it'll back fire out of the front cylinder only. Called the shop back to ask and he said that my slow jet is probably messed up and if I bring it back to him I'm lookin at around $100 to get him to work on it, I'm trying to learn as much as I can about the bike and save as much as possible please any advice will be greatly appreciated, I'm still learning but feel stuck right now, Thanks in advance for any help you guys can come up with!
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  #2  
Old 11th September 2012
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Probably some crap in a carb passageway. Have you flushed out your gas tank? Try running some Seafoam additive in there too.

John
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Old 11th September 2012
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My guess is the intake seals dried out while it sat so long and you have a large intake leak.
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  #4  
Old 11th September 2012
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Do yourself a favor and put a filter in the line from tank to carb just in case your getting new trash in after cleaning and take a look at the accelerator pump diaphragm to make sure little pieces of it aren't contaminating your freshly cleaned carb. I only mention that because it happened to me and it had me very frustrated trying to figure it out. You'll have to reclean the carb and make sure the jets are not partially blocked.
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Old 11th September 2012
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Quote:
Originally Posted by Shu View Post
My guess is the intake seals dried out while it sat so long and you have a large intake leak.
This is a definite possibility also.
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Old 11th September 2012
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John Harper I have not flushed the old gas out of my tank yet, about to put a new sealed tank on it, but was wanting to get it running first. Shu I put a brand new "U-ring" on the intake manifold to the carb. chopfather I was warned again putting an inline filter due to the position it would be in right above and between the cylinders and could possibly start to vapor lock, the accelerator pump diaphragm is brand new as well. It was suggested that the slow jet is blocked how can I clean it/remove the obstruction? Possibly a piece of solid wire maybe safety wire to poke it out? What would changing the slow jet do as far as a new one possibly a bigger one? It's super small but looks like a 48 but the one already installed in the carb is a 45 I think.
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Old 11th September 2012
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The seals that are prone to drying out and leaking are the intake to head seals not so much the intake to carb seal you replaced. The ones I mention are really common especially on bikes that sit a lot.

To check the pilot jet is easy. Drop the float bowl. Remove pilot jet. Hold up to light. If you can see through it it isnt clogged. If you can't then I use compressed are to blow backwards through it and or a small diameter wire feeler gauge. If it isn't clogged and your idle mixture screw is properly tuned then I would suggest replacing the intake seals. Did you get the slide diaphragm back in correctly? Watch the slide action while running and using the throttle to make sure it raises and falls with throttle action.
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Old 15th September 2012
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I swapped out the slow jet and emptied the bad gas out of the tank put some fresh gas in and she fired up fine runs pretty good, but I haven't ridden much other than a short test ride due to some front brake mounting issues I luckily dicovered before it got worse so now I'm just awaiting some parts and I'll be able to start actually riding and shake her down a little more. Thank you all for all of the help!
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Old 8th June 2014
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Default '95 Hugger

I have a '95 Hugger also and had the same exact problem. When I bought it I was told it sat for a while. The problem turned out to be an intake leak on the front manifold. Easily fixed by replacing the gaskets. Hope this helps.
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Old 8th June 2014
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Quote:
Originally Posted by Dink View Post
I swapped out the slow jet and emptied the bad gas out of the tank put some fresh gas in and she fired up fine runs pretty good, but I haven't ridden much other than a short test ride due to some front brake mounting issues I luckily dicovered before it got worse so now I'm just awaiting some parts and I'll be able to start actually riding and shake her down a little more. Thank you all for all of the help!

So, you are using a 48 pilot jet in an 883 which it would never need if everything was set up right. I suspect that you have an intake seal leak as Shu has suggested. You should check the intake seals by directing propane from an unlit torch around them to see if your idle speed changes. Something is wrong if your 883 needs a 48 pilot jet!
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