Drastically need help. PLEASE

[stomper]

A bit of history on my situation. I say history because this has been an ongoing situation for three years now. The only good thing that came out of it was I got so frustrated that I went out and bought a new viper.
2003 Rx1 was gunning great except for a slightly rough idle. Decided to pull the carbs and clean them like I have done on numerous occasions before without issue. Put them back on and it idles great but bogs once it starts moving. If I operate the choke I can actually drive it but it runs rough. I have had the carbs off and cleaned them 8 times in total trying to figure this out. I have replace the seats and needles. All passages and jets are clean. I have ruled out the complete fuel delivery system by bypassing it with a low pressure electric fuel pump and the issue remains. I bypassed the TORS and it didn’t make a difference. My way of thinking is it is something that effects the whole carb rack because I believe if it was only one carb that was the issue it would still run somewhat. I am 99.9% sure that I did not mix up the pilot jets and main jets. I know that can happen but I know I checked the last few times I had the carbs off. But just for curiosity sake, what would it run like if the pilots and mains were mixed up.

 

[STAIN]

you cant mix the pilot and main BUT you can mix the power jet and main jet----it will run like crap. #16 is the main #28 is the power jet
https://www.babbittsonline.com/oemparts/a/yam/5003c034f8700212fc8411ab/carburetor

 

[stomper]

Thanks Stain, I guess I will pull the carbs AGAIN and double check just to ease my mind. Is there a way to check them without complete removal of the carbs

 

[STAIN]

no

 

[RobX-1]

I know you stated you replaced the needle and seats but you're almost describing the exact situation I had with my RX-1. Throughout the years, I never had an issue with removing and cleaning the carbs (ie. soaking jets in Napa's parts solution as well as spraying with Gumout carb cleaner) annually and even bought a mercury carb sync'er to finish the job right; which could also be the root of your problem if it hasn't been done. Two years ago after doing the yearly maintenance, I could not get the carbs to sync like I had been able to do where all four lines of mercury were at the same level. In this state, the RX-1 idled fine but ran like crap; especially at full throttle. I can't tell you how many times I had the carbs off but still could not sync all four carbs together. I even bought a fuel pump rebuild kits (not so much as I wanted to but buggered up one of the gaskets during disassembly ). I honestly did not believe any of the jets needed to be replaced as I could see thru all orifices in the jets. I came to the conclusion that due to the age of the jets, they possibly tarnished up but not something noticeable to the naked eye. Since I hadn't replaced the needle and seats, when I did, I also replaced all of the jets, o-rings and such and also replaced the in-tank fuel filters. They are pain to replace but if you have one of those flexible bolt grabbers, you can snag the fuel lines and just barely get the filter out to replace with new. I did have one of the tank filters practically fall apart, the stem the fuel line connects and the round filter the stem passes thru came apart, so this maybe something to consider as well. Once I did all of this, the ole beast was back to its old form to the point I could now sync the carbs and get a consistent level across all four carbs and the issue of running rough when getting into the throttle was non-existent. Not saying you need to do all of this but just letting you know we had similar issues and this was what resolved mime.

 

[stomper]

I know you stated you replaced the needle and seats but you're almost describing the exact situation I had with my RX-1. Throughout the years, I never had an issue with removing and cleaning the carbs (ie. soaking jets in Napa's parts solution as well as spraying with Gumout carb cleaner) annually and even bought a mercury carb sync'er to finish the job right; which could also be the root of your problem if it hasn't been done. Two years ago after doing the yearly maintenance, I could not get the carbs to sync like I had been able to do where all four lines of mercury were at the same level. In this state, the RX-1 idled fine but ran like crap; especially at full throttle. I can't tell you how many times I had the carbs off but still could not sync all four carbs together. I even bought a fuel pump rebuild kits (not so much as I wanted to but buggered up one of the gaskets during disassembly ). I honestly did not believe any of the jets needed to be replaced as I could see thru all orifices in the jets. I came to the conclusion that due to the age of the jets, they possibly tarnished up but not something noticeable to the naked eye. Since I hadn't replaced the needle and seats, when I did, I also replaced all of the jets, o-rings and such and also replaced the in-tank fuel filters. They are pain to replace but if you have one of those flexible bolt grabbers, you can snag the fuel lines and just barely get the filter out to replace with new. I did have one of the tank filters practically fall apart, the stem the fuel line connects and the round filter the stem passes thru came apart, so this maybe something to consider as well. Once I did all of this, the ole beast was back to its old form to the point I could now sync the carbs and get a consistent level across all four carbs and the issue of running rough when getting into the throttle was non-existent. Not saying you need to do all of this but just letting you know we had similar issues and this was what resolved mime.

Haha this is like deja vu. We have discussed this before Rob. I just went back and found my old thread on this. https://ty4stroke.com/threads/carb-question.155838/. I pulled the carbs off again and checked the mains and power jets and they are in the right spots
I checked the prices from my local yamaha dealer here in canada and the prices are rediculous to buy the parts indivudually soI found the All Balls complete carb kit I am going to give a try. https://www.totalpowerparts.com/all...uild-kit-26-1895-for-yamaha-rx-warrior-04-05/
It has everything I should need including gaskets and orings. These carbs have been apart so many times that i'm sure some of the rubber components need repacing. My main jets are 165 instead of the stock 135 because I have an airbox mod. The kit comes with the stock 135 jets, will they work instead of the 165's even thought i have an air box mod

 

[RobX-1]

Talk about deja vu I too run ECP (K&N filters) kit and had to purchase new 165s as you’ll need the larger jet due to loss of vacuum with air box mod

 

[stomper]

So are jets for mukini carbs all the same style or do I have to get specific ones for the rx1. Reason I ask is i have a polaris dealership in town where I may be able to get them but my closest yamaha dealership is 1.5 hours away

 

[74Nitro]

The problem might just be that the CV carbs do not function properly with modded airbox. Try it with the stock airbox in place, with all stock settings.

 

[stomper]

The stock air box it whats on there right now, but it's modded. I did the Sled Dog air box mod on it so I don't have a "stock" air box

 

[RobX-1]

So are jets for mukini carbs all the same style or do I have to get specific ones for the rx1. Reason I ask is i have a polaris dealership in town where I may be able to get them but my closest yamaha dealership is 1.5 hours away

That I'm not sure of as I just replaced with OEM part # 3G2-14231-33-00. I've seen them on-line for under $6 but also have to factor in shipping plus with you being up on Canada and having to deal with customs, is probably a hassle for you. Maybe check with "local" dealer to see if they would be willing to ship them to you where you pay shipping cost so as to not have to drive the 3 hours.

 

[74Nitro]

Get a stock air box to try.
Another thing you could try is hold your hand over the opening of the airbox and try to rev it. I'm assuming the opening of the airbox has been made larger.

 

[stomper]

Get a stock air box to try.
Another thing you could try is hold your hand over the opening of the airbox and try to rev it. I'm assuming the opening of the airbox has been made larger.

It will be much easier to buy 4 new #165 jets than find a stock air box. The sled has run great for four years with the air box mod so thats not a factor in the issue that I am having

 

[74Nitro]

In your first post you said the problem has been going on for three years.
In addition, the pilot and main jet cannot interchange, the thread diameter is different.

 

[74Nitro]

In your first post you said the problem has been going on for three years.
In addition, the pilot and main jet cannot interchange, the thread diameter is different.

However, the choke circuit jet and main jet can interchange.