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Old 03-25-2006   #1 (permalink)
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Did the baffle removal and today replaced the 110 main's with 115's, ran great for a while then started backfiring, stalling and died. I checked the spark plugs and they looked normal so I switched back to the 110's and it won't start.
Took the bowls apart again and checked the jets and rechecked that the spacers were in. Any ideas?
Thanks
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Old 03-26-2006   #2 (permalink)
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Kinked vent hose? Did you have the tank off? Out of fuel? Is there fuel in the bowls? Unscrew one of the drain plugs in the bowl. Plugs fouled? Pull one and see if it is black and wet. Good luck-T1
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Old 03-26-2006   #3 (permalink)
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I kept the tank on and fuel and plugs ok but when I rejetted I took out the jet and the jet holder as one piece from below with just the bowls removed, screwed in the new jets into the jet holders then put the holders with those spacers back into the carbs. Is it possible do do some damage to the needles when I screwed the jet holder back in place? Also I will check any vacuum lines going to the carbs today in case I pulled something when removing the bowls.

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Old 03-26-2006   #4 (permalink)
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When you remove the main jet holder with the carbs on the bike, the needle jet will fall out and the left one will drop behind battery and wires if you don't catch it. Make sure they are not re-installed backwards.
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Old 03-26-2006   #5 (permalink)
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Since it ran for a while it sounds like a vacuum line fell off. It's sucking air from some place causing the backfire. It's definitely not getting enough gas or too much air. :???:
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Old 03-26-2006   #6 (permalink)
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Still no start.
Today I pulled off the tank and top covers on the carbs, pulled the needles and checked and them, also pulled the main jets to check them and reinstalled. Those needle jets are in place with the large opening up and the small opening down on the main jets (please verify that this is correct). Checked the vacuum hoses to the carbs and everything seemed ok, does anyone have a vacuum diagram to post so I can trace every line there is (I only checked the carb lines).

Thanks for the advice
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Old 03-26-2006   #7 (permalink)
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"..ran great for awhile...." How long a time was that or how many miles approximately?

I assume you placed the needle jets back in correctly or you would have had problems pretty quickly--as in too rich is my guess. If you got them correct the first time I would assume you got them correct the second time. One way they fit and seat properly--the other way they do not seat properly. If you could look in the back of the carbs (airbox doesn't allow it readily) you could see if the needle jets were seated properly.

"...backfiring...." I don't associate backfiring with fuel problems--I associate backfiring with ignition problems. Popping on decel is something different in my book. If you pull off one of the vacuum caps, you will get a lot of popping on decel; however, it will run without popping when you are at constant throttle or accelerating--at least that is what mine did when I lost a cap.

Since it ran good before you worked on it, I would be just like you and assume the problem was caused by my recent work. After you check the fuel really well, I suggest checking the ignition.

The needle jets sit in the top part of the needle jet holder and the main jets screw into the bottom of the needle jet holder. The needle jet holder holds the needle jets partially into the throat of the carb--that is why you can view them from the air filter side of the carb and tell if they are properly seated.

Is there any chance your bike is a California model?

Larry
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Old 03-27-2006   #8 (permalink)
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Yeah Larry I am starting to think ignition may be the problem. After the rejet I rode for about a mile and it ran great, shut down the bike and a couple of hours later it barely started and ran rough then not at all, even went back to the original jets and nothing. I am confident that the needles went back in well. Today I will check for spark and maybe go from there. I went through everything else that I could think of, fuses, spark plugs, fuel in the bowls.

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Old 03-27-2006   #9 (permalink)
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Oh forgot it is not the CA model and I only have 700 miles on it so if it is the ignition I will take it in for the warranty.
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Old 03-27-2006   #10 (permalink)
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Some have had the crank position sensor fail with low miles on the bike. Hard to guess at the cause if it is ignition--if no spark, call dealer and have him come get it and trailer it in to fix would be my recommendation. I assume you bought a new 2004 from your dealer.

Larry
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