92 CR500 pissing fuel from float bowl vent line after PWK/AS install

Hello all! I just bought a 92 CR500 which has been sitting for 5 years. I replaced the carb (orig PJ) with a 38mm Keihin PWK Airstriker from JD Jetting and fuel line. I installed the jets as instructed: Blue needle, clip 3. Pilot 45, Main 175, I'm in Michigan btw. When I finally got everything reinstalled and fired up the bike I turned on the fuel petcock, on with the choke, tipped the bike to the left side and kicked it over and she started right up. She was however pi$$ing gas at an alarming pace from the vent line closest to the float bowl nut, lower part of the carb. I should mention before the new carb was purchased she would not idle or really run without choke. 

Every time I turn on the fuel petcock gas pours from that same vent line. Did I blow it installing the jets? I am not sure?  I have a feeling I'm forgetting something....Any help would very very appreciated. When it was running throttle blips were seeming correct...just gas flowing from that vent line???

Thanks in advance!

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Float height?

Float height...sadly I don't know. Exactly how it was when it arrived from JD Jetting. It didn't come with any mention of float height in the documentation. I've read about that but assumed since it was new it would not need adjusting??? I'm guessing that is a sub par assumption...dang I don't wanna take the carb back out again !!  I am unclear on how to adjust float height if that's whats needed.

how about tapping on the float bowl with the plastic end of a screw driver or something... sometimes floats stick even if they are new.

I'll try it and report back tomorrow. The stock rubber intake boot from the airbox and into the cylinder ....it appears the carb is leaned a bit too far left??? I tightened the screws etc...lined up with the metal piece on the carb up against the notch in the rubber. Could be in my head...

Make it level as possible, a significant lean won't help matters either.

x2 on what Demi said,  sometimes things stick, use a small rubber mallet and give it a few taps.  

If that doesn't work you need to check your float height and the float needle (stop plug operated by the float) and make sure it is sealing.

I typically take the bowl off, stuff some rags under the carb over the engine to catch fuel, then manually move the floats up till you see the float needle closes completely.  Turn the fuel on.  If fuel comes out at full close you have a needle issue, either dirt or it is damaged/goofy/sticking, i think there might be a seal inside as well but never had that issue... yet.  If no fuel, slowly drop the floats until fuel starts to come out and take note of what the needle is doing and where the floats are.   Is the fuel coming out while the needle is still "closed", bad needle or tension, obstruction ect...  is the fuel coming out because the needle is dropping while the floats are still in a really "high" position?  Could be tension on the needle is bad or the floats are set too high.   If everything seems to function correctly but height is just off take a measurement where the fuel goes from barely coming out to stopped, this is your current height, check it vs recommended and set accordingly.

Clean the float mechanism while you are in there, basically anything that moves or seals to ensure that everything is moving freely, no friction and what not.

Most people will tell you to pull the carb to set the height but if you do it like this it is quick and easy, once you get used doing it you don't make much of a mess and waste very little fuel and again it is a great way to visually see that the float needle is functioning as it should.  :thumbsup:

just my method, take it or leave it.  

Had the same thing on a brand new AS I bought for the AF, Float height on the 38mm, screw cap, AS is 19 mm, PJ motorsports a carb specialist in Oregon was kind enough to check with their tech. They won't help with jetting though, top secret. :naughty: Runs perfect now, starts easy. Nice steely btw. Welcome to the brotherhood.  :applause:

Edited by 87' CR 5003
Float height...sadly I don't know. Exactly how it was when it arrived from JD Jetting. It didn't come with any mention of float height in the documentation. I've read about that but assumed since it was new it would not need adjusting??? I'm guessing that is a sub par assumption...dang I don't wanna take the carb back out again !!  I am unclear on how to adjust float height if that's whats needed.

Always set your float height. I ride woods so I always set mine a tad lower than spec.

Thanks to all who have commented!!  I'm going out to my garage shortly and try the some of the suggestions but I suspect I'll have to set the float height. I believe I did everything else exactly right.....but I have no idea how to set the float height....any tutorials or instructions anywhere? Nothing referring to float height in my paperwork from JD and I'm not very experienced in this area.

46 minutes ago, fredorama said:

Thanks to all who have commented!!  I'm going out to my garage shortly and try the some of the suggestions but I suspect I'll have to set the float height. I believe I did everything else exactly right.....but I have no idea how to set the float height....any tutorials or instructions anywhere? Nothing referring to float height in my paperwork from JD and I'm not very experienced in this area.

Checking............

 

Just the basics, Main thing is the tab should just CONTACT the plunger on the inlet needle, It's spring loaded so DO NOT collapse the plunger when taking your measurement.  :thinking:

So....pretty good news...I straightened the carb up to be as close to level as possible with the bike standing upright, couple taps on the float bowl area, choked her, third kick she fires up!

Not a drop from the float vent tube!

She would not idle though, so cranked the air screw in all the way, back out to 1.5 turns, fired it back up and cranked in the idle screw until she idled!!

Seeing as I never touched the float bowl level should I still do so? I do feel much better but I defer to the experts???

great, you can buy a round to settle up! enjoy the beast. I would just ride.

I'd run it first, if there is a problem with the height you should notice something

Well I took it for a spin against better judgement but I was desperate!!  At the point I should have turned around and headed home I chose to head up a dirt road leading to the next phase of my subdivision. Bad move, what was a short test ride turned to a nightmare as I got half way up the road and encountered foot deep ruts from earth movers, with 3-6 inches of mud from the 2 inches of rain we had yesterday on top of them. It was like riding on grease, worse than ice. I had to keep moving couldn't stop I thought I'd get to the top of the road/hill and sneakout on the main road for a 1/4 mile run back to the street I needed. Well nope I bit it at least 7-8 times uphill in the grease not hard but sure sucked....the upside is the bike started right back up each time and seemed to run real well. I didn't get but one chance to nail it on the first dirt road and she felt good. It certainly warrants much more analysis but we have snow coming so who knows when that will happen!!!  What kind of symptoms should I try to be looking for regarding the float bowls???  

 

Pulled the crap out of my groin getting on and off the bike 50 times during this little adventure, would have won an award if it could have been filmed :) tomorrow morning I bet will see some pain!!

 

Good night and thanks all in advance for everything!!  She did get a hot bath when I got back and my family was laughing butts off.

i have been on test rides like that :cool:

2 hours ago, fredorama said:

Well I took it for a spin against better judgement but I was desperate!!  At the point I should have turned around and headed home I chose to head up a dirt road leading to the next phase of my subdivision. Bad move, what was a short test ride turned to a nightmare as I got half way up the road and encountered foot deep ruts from earth movers, with 3-6 inches of mud from the 2 inches of rain we had yesterday on top of them. It was like riding on grease, worse than ice. I had to keep moving couldn't stop I thought I'd get to the top of the road/hill and sneakout on the main road for a 1/4 mile run back to the street I needed. Well nope I bit it at least 7-8 times uphill in the grease not hard but sure sucked....the upside is the bike started right back up each time and seemed to run real well. I didn't get but one chance to nail it on the first dirt road and she felt good. It certainly warrants much more analysis but we have snow coming so who knows when that will happen!!!  What kind of symptoms should I try to be looking for regarding the float bowls???  

 

Pulled the crap out of my groin getting on and off the bike 50 times during this little adventure, would have won an award if it could have been filmed :) tomorrow morning I bet will see some pain!!

 

Good night and thanks all in advance for everything!!  She did get a hot bath when I got back and my family was laughing butts off.

Sweet !!! :applause: Heal up, Clean up, New word in your lexicon will be " Short shift ".  Being that you're in Mich. school starts when things dry up there. Luckily you've got a whole bunch of GOOD teachers on here. :ride: Take advantage of it.

If the bowl isn't puking fuel out of the overflow (too high) and the bike isn't stalling when opening the throttle in a corner (ask me how I know that symptom :( too low) then you are prolly pretty close and I wouldn't worry.

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