Sportster loses power and dies
 

Hey everyone,

I have a 97 sportster 1200xl with a stock Keihin carb. I cleaned/rebuilt the carb and went for about an 1 1/2 hour ride down Natchez Trace without any issues.

Unfortunately, the next time I decided to ride, it ran for a few miles and decided to lose power and die. It's almost like it wasn't getting enough gas. It was a cold day (32F) so before I started riding, I warmed it up, and rode without the choke for a few miles before it died. It idled with and without the choke just fine, but then died once I started riding down the road... with or without the choke.

What did I screw up? I'm happy to provide additional info and any help is appreciated. Thanks in advance.

Sounds like something is wrong with your main jet or needle, assuming the throttle is opening and closing fine. You're probably going to need to pull the carb and the bowl and check it out.

If your bike still has the stock vacuum fuel tap, they are renown for causing problems. It may simply be that your carb is filling up and then the vacuum isn't being maintained. Check the vacuum hoses between carb, tap and VOES. Your bike is 20 years old and it would be a good idea to scrap the vacuum tap and buy a normal one.

I took apart the carb, main jet and needle look good. Throttle plate is opening without any issue. I tested the float needle and it is stopping flow like it should after the float levels out. Now that I'm thinking about it, the bike only started to lose power in higher gears (3+) when the throttle was almost wide open.

Are you sure the needle jet didn't fall out when you cleaned the carb? It happens fairly frequently.
(Silver piece the needle passes through, pointed at by the red arrow)

I'd agree with the above post on the vacuum line to the petcock. I'd check the fuel filter and all gass lines while your at it.