The CV is a darn good one. And I agree do not drill. My current CV is 25 years old and still never been apart of failed me

 

I have been running the Dynojet kit for about 5 years. It works well and I have the same carb you have. I rebuilt the carb in 2016 and took the advice of a friend who was a Harley mechanic to use the Dynojet kit. It's very simple, you just install new jets according to the instructions (running performance air filter, pipes etc.) then you use the drill bit that comes with the kit to install their needle. Result is a lot more low-end grunt because the bigger needle lets in more fuel off the line. After 15 years the soft parts in my carb had rotted, so I replaced all the rubber, primer pump, o-rings and gaskets. Bike runs fantastic. Also, the "B" I think only has to do with the year, but since you're doing all the jets and a rebuild I doubt any real differences will matter because you're changing everything.

 

^^^That right there is some great advice. Especially once you can't un-drill what you drilled...

Also, betting you boogered up the screws looking at the screwdriver you used - get a JIS screwdriver from Amazon for 10$ and prepare to be amazed... Those are not #2 phillips.

 

LMAO Well lets just say t150vej can be a blunt as a bowling ball.

Ha as a rule has good advice

WP

 

Get rid of the screws and go with Allen Head bolts.

 

M4 x .7 x 10mm

 

Already done. 5mm socket caps in already. Changed the fuel line as well.

However I’m kinda stumped. Everything is back together. I pulled the Dynojet kit as recommended and used the stock parts as it came to me, only changing the main jet to 180. Left the 45.

However I can’t get it to stop pissing gas out of the overflow. I fabricated a 16deg incline and measured the float height at precisely 11mm about 17 times (range is 10.5 -11.6, yet as soon as it starts running (and it runs perfectly) it starts pissing fuel out the overflow, nonstop. I checked the float valve and as far as I can tell it looks clean and intact.. This is the spare carb I rebuilt using the rebuild kit - I cleaned everything sparkling new, and yet this is the situation. The Stock carb (the one that originally leaked from the overflow, causing the start of this whole debacle) already had a dynojet kit in it, judging from the emulsion tube and accelerator pump sprayer. Guess the prev owner had it installed with his stage 1. Both have a needle with a c-clip on the third position with three washers under them. However the vacuum hole on the slide doesn’t look drilled - it’s smaller then the drill bit that came with the dynojet kit I bought.

 

Let's address this overflow problem. First, is this the 1999 FXR2, and one of the carbs is original to it as far as you know? (I'll assume the other is off an unknown, no problem)

Is the petcock the original? (It should be a vacuum operated)

Do one or both or your carbs actually have the drain screw, external overflow nipple and brass pipe in the bowl?

 

Yes, the stock carb is original as far as I am aware. Disassembly shows all stock components except for the needle and keys. Has an adjustable jet of unknown origin set at the middle setting (3 positions down) with three washers below it. It has a stock emulsion tube and a 180 main jet, and a 45 idle jet. At this point I just want to repair the overflow as it ran great prior. I went to HD and bought a float valve and a bowl o-ring and installed them. Set the bowl level to 10.9mm and am about to install it back and try it out. I’ll report back in 10 min.

 

Don`t forget to replace the fuel line, it can often be the source of the debris that fouls the needle and seat.