Bike had been sitting changed all fluids, charged battery and she started right up. but won't run without the choke on. Told it was a simple fix. pull carb and clean jets. can't seem to figure out just how your suppose to pull the carb
REMOVAL
1WARNING
Turn the fuel supply valve to OFF and then remove the air cleaner and backplate, cut the clamp and disconnect the fuel hose from the fuel inlet fitting, detach the enrichener knob assembly from its bracket between the cylinder heads, disconnect the throttle cables from the carburetor, disconnect the fuel overflow/drain hose from the fuel overflow fitting, remove the enrichener cable assembly, enrichener valve and spring. (on California models only, disconnect the canister purge hose from the fitting on the carburetor body), remove the fuel tank and pull the carburetor free of the intake manifold. If removing the intake manifold, remove the four manifold mounting screws, remove the intake manifold, the seal ring, the mounting flanges and the two intake manifold seals. If removing the MAP sensor remove its screw, the MAP sensor clip and the MAP sensor itself.
SOURCE: Hi, I have a 2004
The service manual says to "remove the carb" for this job.
But yes you can remove the main jet out without removing the carb out.
You can rotate the carb and slide it off the intake, but watch how much slack you have in the cables, remove the bottom plug that adjusts the fuel mixture.Take the seat/tank off and loosen both the 3mm bolt and philips mounting screw so you could turn the carb to were you could remove the big bottom 17mm bolt .
When you look up into the bolt hole with a light you can see two access holes for both the main and the pilot jets.the pilot can be changed by tilting the carb bottom to the left and removing the big bolt on the bottom. It's accessible without removing the float bowl. To get the needle out, you need to pull the seat and tank, remove the carb top cover (3mm allen bolts), remove the 4mm allen bolt on top of the slide, being careful not to lose the spring and other parts (3 pieces total). Pull the needle out with a needle nose and you're set. The main jet is replacable from the 17mm cap on the bottom. Your needle tube/jet may come out with the main jet but is no biggy. You can drain the float bowl before doing it if you loosen the little 3mm bolt on the bottom of the bowl. Just be sure to readjust the throttle cables after you move the carb back. Tilting the carb pulls all the slack out of the cables and the bind a bit if you dont pull them back.
You can remove the main jet with a main jet tool or a 1/4 inch socket. If the needle tube jet (long skinny tube that the main jet threads into) comes out with the main jet, simply unscrew it from the main jet with an 8mm wrench and the tool you used to take out the main jet.You can put the new main jet back in the tube first and then replace the tube back into the carb. The needle will be hanging out of the bottom of the carb where the tube goes. Because you have the carb at an angle the needle will be hanging at an angle, so you need to "thread" the needle into the tube to get it to go back in.Be sure not to over tighten the main jet because you can break it off. Also when you turn the carb, the front boot can turn if it is not tight (this is common on this bike). Be sure to line up the notch on the bottom front intake boot and tighten the front clamp. It is hidden under the crankcase vent hose that runs over the top of the boot.
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SOURCE: 98 Sportster 883. starts & w/ choke, won't
No, nothing else to check. You need to completely disassemble the carb and clean it out. When gasoline left in the float bowl evaporated, it left behind the gummy additives that the refinery puts in the gasoline. This mess has clogged the jets and small passageways in the carb. The reason it runs with the "choke" out is that it is not a real "choke" but rather an "enricher circuit". It has it's own air passageway and fuel metering "jet" in the float bowl.
Good Luck
steve
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