Well, I got it all buttoned up back together last night, and it still won't run without the choke. It had to crank quite a bit before it would even try and fire.
I've been playing with it today, and the bike seems to immediately die when it starts.
What I've Done:
Removed and Cleaned/regapped to .031 all spark plugs
New Gas with Fuel System Cleaner
Removed Carb from Bike, cleaned out bowl, both jets, bowl drain screw, floats. Confirmed float allows gas(or carb cleaner) to flow into bowl by gently manually actuating the float and needle. The jets all soaked for 24 hours in carb cleaner, were soft wire brushed clean, resprayed, and compressed air blasted.
New Fuel Filter (bike is 2003) and I've confirmed the arrow on the fuel filter is going into the bike. There is no screen in the main line to the carburetor on the 2003.
Visually inspected all removed hoses for cracks/breaks, etc. Replaced as needed.
I checked the diapgram in the dark with a LED flashlight, no cracks or pin holes seen.
Accelerator pump circuit was cleaned.
I removed the A/F screw, spring, washer and o-ring. Cleaned and replaced. Screwed it until gently snug, then backed out 2 1/4 turns.
The Idle Speed has been adjusted so that the CAM is raised approx 1/4". So it's ballpark in the right place for approx 900rpms.
I ended up not doing the SCAR mod, only because the bike is stock except the Hard Chrome exhaust, and should run fine.
So it's now worse after having cleaned everything out. The bike won't stay running. I followed this thread over on vtxcafe because it was about the closest issue I found that explained how to do stuff, etc. I had almost identical initial issues, except my bike would only run with the choke out about 1/4 of the way.
From start to finish, besides replacing the jets with the FP kit, it looks like I've done everything he did. I did confirm the O-ring on the A/F mixture screw he was missing was in place and in good shape.
Also, my main spring ( the one in the diapram) is only about 7.5" long. I've read in a few places there are short 5" springs in the re-jet kids, or the stock one is 9" long... Anyone got any ideas on this? Maybe I have the correct, factory spring.
I'm guessing something isn't plugged in correctly.
This happens with or without the choke on. No different. Runs the same 1/2 second before shutting off.
Is there something silly i forgot to plug back in? I'm was wondering if the diagram isn't seated correctly in the groove for the piston, but I took it off and its perfectly in the groove.
if I keep rolling on and off the throttle quickly, the bike will stay running, but won't idle. I've tried adjusting the idle speed up a few turns, and back down to no avail, no difference at all.
I didn't have any "extra" parts when I put it all back together, so there must be something connected wrong. If I run the bike without the air cleaner and I put my hand over the stock intake hole, the engine seems to straighten out for a second before it dies. So I'm guessing there is a big vacuum leak somewhere, but I can't Identify where. Both of the hoses are connected on the back of the intake, nothing seems to be out of place.
The gasket is in place between the intake and in the carb. The hose clamps on the carb to the manifold are tight. Maybe the bowl gasket didn't seat correctly? I'm sort of out of ideas of where to look.