When you say you cleaned it up, did you use compressed air? If you don't have a compressor at the very least buy a can of carb & choke cleaner that comes with a straw and use that to shoot thru the jets and by-pass holes and what not. Check and make sure that the carbs vent is open/free. Good luck

 

Here is how to solve your problem: (smug reply).

You will have to remove the fuel bowl at least one more time, check and make sure that the spring in the needle that shuts the fuel off when the float rises in the bowl is working, next make sure when you re-install the float that the needle is engaged on the face of the tang and the little spring that you can't see is working. Do this by lifting up on the float gently and make sure the needle seats before the float reaches full travel.

Check to make sure the float seats the needle before it is in a level position, this will keep fuel from getting into the over flow, make sure the over flow tube is clear and free of insects, or other debris. If the float is set to high, excessive level in bowl, it won't have much effect on the engine because when the engine is running even at idle it will suck enough fuel to compensate. Fuel will run out the over flow if the float level is set to high.

Idle mixture is on bottom of carb, Idle adjustment is on right side of carb when facing the bike on carb side.

Idle mixture screw takes the bike up to about 65mph. From there the high speed jet comes into play, but since it takes awhile for the engine to recover I'd bet it is the fuel level that is off.

Sometimes you will never get it "right", and you'll just have to remember to shut the fuel off at the tank when you shut down, otherwise fuel will run out of the bowl overflow.

On the positive side, if you set the level a little high, the little rubber tip will eventually wear itself in and make a good seal. Check to make sure there is a rubber tip on the shut off needle.

 

miacycles, man u sure know your stuff! I wish you were in my town! I was looking at a care and feeding of the cv carb page by a kawasaki rider and I see this picture. I look at the part I circled in red. Its the part my gf picked up off the driveway when i was rolling the bike into the garage! I couldnt have it in backwards because it wasnt there! Glad I didnt just throw it out!

Thanks everyone for the advice and encouragement! Now I can sleep and try again tomorrow!

 

Oh, and thanks for the offer of the free fix but most of my problems(like this one) are self inflicted! Your excellent advice is more than enough!

 

Are you speaking about the needle jet (number 5 in the pic)? That will do it. Glad you found it. These can easily fall out and will certainly shoot fuel out of the carb if not installed. I have personal experience with it

 

That is the most common problem with carbs rebuilt by their owners, followed by diaphragm problems. By the way I am moving to Bluffton,SC, just outside of Hilton Head. I guess I could lie and say I am doing to get closer to you, so I can help you LOL

 

John,

It's always good to see you on the boards and read your helpful insights.

You're a friend to all of us EVO owners ... Thank You Sir!

 

Aw shucks--You're embarassing me-- But don't stop LOL. South Carolina bound in around a week. Have most of the shop packed up. Have a guy coming over to look at some of the extra welders, etc.

 

Good luck with the move! Sorry I didnt update. Needed to get away from it for a bit. That was part of the problem but didn't solve everything. I can get it to idle somewhat smoothly but when I put it in gear and try to take off it just dies out. I was going to take it into the shop tomorrow but I can't get it running well enough to get there so I took it off tonight and took it apart cleaned it up again. Am going to get a rebuild kit in the am and do it right. The only thing I know for sure is it was running as good as it ever did before I took it apart so it has to be something I did. So wish me luck maybe I can undo whatever it is I didP ! Just one more question, should the float bowl rattle? If I take it off the bottom of the carb and shake it something rattles.

 

I think your agonizing over it (float). It may rattle, (I've heard of that in an old '60's float, bit of solder inside),look for pin holes in the float, after blowing it clean! Or buy a new float. If the float was leaking (or had pin holes) you should see fuel on the ground, via the overflow tube.

If it barely runs + puts out black smoke. Did you look at the plugs to see if one or both cyclinders are too rich?

It maybe that your overflow tube is plug, dumping fuel into the engine? Is the oil smelling of fuel?