Carb problems

[Waldron]

Ok, I'm kinda stumped here. I bought my 1200S about 3 months ago. When I got it, it had some rust in the fuel tank. The first time I put it on reserve, it started running poorly (it felt like the pilot jet on one cylinder was clogged). I took the carbs apart, cleaned them out, and put it together and everything was fine, but I didn't clean out the tank. I meant to, but didn't get to it. The other day I had to switch to reserve again, and it happened again. So I took the carbs apart, cleaned them, took the petcock apart and cleaned it, and flushed out the tank. Now the problems start:

   It won't go over about 3K rpm. If I crank on full choke it will go as high a 4k, but that's it. I'm assuming I messed up somewhere in the needle circuit, and I have one idea about where. Which way do the little barrel-shaped inserts that the needles go through face? On Ron Ayers fiche ( http://www.ronayers.com/fiche/300_0315/carburetor/carburetor.cfm?man=su&groupid=4760&parent=4740 ) it's part #12; they call it a "jet, needle". One end is convex, and the other looks like it was made by drilling into the insert. The first time I put it together, I could have sworn I had them with the drilled end up, but when I went to assemble it, they didn't seem to fit that way. I didn't want to force them, so I put them in convex-side up. So, is that where I muffed it, or can you guys think of something else? Help; it's a beautiful day, and I want to ride!

[pmackie]

Hey Waldron

I'm not completely familiar with the 1200 carbs (I have the 600) but it is unlikely that you could install the needle jets upside-down. On most carbs they either screw or are pressed into the holder (#13) which then screws or is pressed into the carb body, with the main jet assessable at the end.

The first thing I would do is inspect and/or replace the factory inline fuel filter.
2nd - clean the needle valve and seat(#16 on your pic), and ensure that the entire fuel supply is clean by blowing out with air.
3rd - ensure the pilot circuit is clean, take out the pilot jets and blow air through all the circuits.

[Waldron]

Hey Waldron
I'm not completely familiar with the 1200 carbs (I have the 600) but it is unlikely that you could install the needle jets upside-down. On most carbs they either screw or are pressed into the holder (#13) which then screws or is pressed into the carb body, with the main jet assessable at the end.

These drop in before the holder goes in, and are then trapped in place by the holder. There are no threads on the jets

The first thing I would do is inspect and/or replace the factory inline fuel filter.

Doesn't have one.

2nd - clean the needle valve and seat(#16 on your pic), and ensure that the entire fuel supply is clean by blowing out with air.

Done.

3rd - ensure the pilot circuit is clean, take out the pilot jets and blow air through all the circuits.

Done.
If someone could take a pic of or describe the view into the carburetor, that would clear things up for me...the jet protrudes into the carb throat about 3mm the way it is now, and that seems wrong. Just pop off one of the pod filters, and take a pic of the carb throat, or tell me if the needle jet sticks up a bit. If I remember, it's not supposed to.