Here we go with Day 3.
First I had to pull the pistons off. I went to the HD store and told them I wanted the tool to remove the piston lock ring. $85 later I was heading home. I went to use it and the end wouldnt fit all the way thru the piston pin. Took it back and a different salesman said it wouldnt work on a sportster.(Even though it says it will in the manual) Got a full refund so not a big deal.

Ended up removing the lock ring the old fashion way. Stuck a small screwdriver under the ring and popped it out. No pics for this cause the camera was in the house. Push piston pin out and pull off piston. Piece of cake.

Rejetting the carb


To drain the bowl...open this screw with a regular screwdriver and the fuel will flow from the hose.
Close when its done draining.



Remove the 4 phillips screws from the bottom of the carb. DO NOT use a screwdriver thats to small otherwise you will strip out the head. Remove the float chamber.

The book says to remove the float, pin and fuel inlet assemble. Do NOT do this. There is no reason for it. You can change both jets without removing this stuff. I should have thought for 2 seconds and I would have realized this. Oh well..live and learn.



RED ARROW....Take a 5/16 wrench and slip it over the end of the nedle jet holder. Then take a regular screwdriver and unscrew the main jet. Replace with a new one. I am using a 180.

GREEN ARROW..Take a long skinny regular screwdriver and unscrew the slow jet. Relace with a new/different size. I installed a 45.

Thats about it. Put float chamber back on and tighten the 4 screws. . Do Not force the float chamber back on. It will go on easy if everything is aligned up right.


Here is where I need a little help. When i took out the needle jet holder (which I didnt have to do) the needle jet fell out. Which end goes into the carb first??? Pic 1 or 2??? Also going to post this question in the carb section.
Pic 1..Flanged end.


Pic 2..Unflanged end


While working on the piston..NRHS called and told me my kit was going into the mail that day (yesterday). Hopefully it will be here Friday so I can finish this up on the weekend. (My truck is getting tired of sitting outside). Final day will be Day 4. Probably not to many pics...Mostly torque specs and what if any problems I run in to.

 

These writeups have been sweet. Nice job!

 

Can't help you with the jet...I forgot which end is first. BTW, just a reminder...got Assembly Lube ??? the wrist pins get a dose and I coated the cylinder innards with 20-50 before inserting the pistons on the bench. You'll put one of the circlips on the wrist pin on the bench (easy). The other is a tad difficult. If your wife can hold the jug in place while you slip the wrist pin through, the start the second circlip inserting one end in the groove, work it around until the other end is inside, then push it all into the groove. Make sure the clip is in the gtoove. I tapped all the way around with a screwdriver and light hammer.
If you didn't need all this...please ignore. Another thing...when you finally start it up the pushrods and valve train are goin to make one hellacious racket until the lifters pump up. It may take about a 10-20 minute ride at breakin speed.

Olesalt

 

My bike is EFI,but I read and enjoyed the article.

Tom

 

Thanks!!! I was wondering earlier today, when you're "day 3" was gonna happen.

This is some awesome 411 you're sharing!![sm=biker.gif]

 

that needle jet holder if you put it in it should stick out into the throat of the carb one way it does the other it doesn't. if you put it in wrong you can only screw in the needle jet a few turns before it gets tight. the right way the needle jet will screw in all the way in. but the holder should go in to where it stick up into the throat of the carb about 1/8" or so. hope that helps

 

The large opening goes in the carbfirst.Trust meI have been there and my service manual states the same.If you are breaking up and have no power after the carb is reinstalled you put it in upside down.

 

This is a very cool post!

 

Don't forget to look , one piston has a stamp that goes with the stampon the matching cylinder.

Else , blow back ...

























Just kidding, or am I ...

 

Nice pics. Keep 'em coming. I'm curious about one thing, though. Why did you go 1250 as opposed to having the stock jugs bored? Are the extra cc's worththemoney? I'm having mine bored, but mostly because I like the stock silver powdercoat on them.