PHBG installatin help please

[BettinANDlosing]

Gas should not be coming out of the two downward facing holes, those are breathers. The large brass one is for gas, the small one near where the carb mounts to the manifold is vacuum, and the small side on is oil line. If you have fuel coming out the breather your float is sticking, or the reeds are messed up and engine sending pressure back into the carb. With the starter and choke, just reach with your left hand and do the choke and hold the brake and hit the starter with you're right. Alternatively you can install a handle bar mounted choke lever.

[Triesandluth]

You didn't use those reeds from the kit, right? I know you had to see the thread on it.
On that note, is your reeds and cage, etc in working order?  I'm not sure if you removed it when modding the intake.

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[TheAmishSasquatch]

Thanks fellas. Yes the reeds are good. They are the stock reeds and cage not the Malossi reeds. No fuel is not coming out of the vent holes. If air is blown into the vent holes, fuel will come out of the carb inlet. All the lines are connected as youve  detailed.  I try to cover all of my bases before posting questions and Im still at a loss. Ive got spark and fuel. Compressions good, starter is good, battery is good, CDI is good, kick starter is bullet proof, kill switch is set to run. In theory everything needed to make the bike run is in place and operable.   WTF!? 

[Triesandluth]

Can't forget that wretched kill switch lol. Mine doesn't work so I always leave that one out.
While we're thinking of all the dumb things, one time I was going crazy about it not starting, called it a night. When I came out the next morning I found that I never put the plug wire back on the plug.
I would say to retrace your steps, but you've done a lot.
Anyways. Best of luck, man! I feel for ya. I'll put in a few extra miles for ya tomorrow!


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[TheAmishSasquatch]

I should have gotten an Aprilia, done the computer flash and added a pipe. Would be just as fast or faster then this worked S9 and It'd be running!!! 

[TheAmishSasquatch]

I'm beginning to wonder if maybe the oiling holes for the piston were drilled in the wrong spot ??

[BettinANDlosing]

I should have gotten an Aprilia, done the computer flash and added a pipe. Would be just as fast or faster then this worked S9 and It'd be running!!! 

Then replace a $300 fuel pump a year later. Those bikes are very overrated, and you think your frustrated now? Try diagnosing one of those Italian POS bikes, if there is ANYTHING wrong it can be a nightmare. Plus it takes 45 minutes to just take the seat plastics off.

[Triesandluth]

I'm beginning to wonder if maybe the oiling holes for the piston were drilled in the wrong spot ??

Did you drill them? I know zombie talked about drilling in the wrist pin, if I remember correctly, and beveling the piston skirt edges...

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Edit, he does say in the spot where the wrist pin goes into the piston. Unless you speak of elsewhere

[TheAmishSasquatch]

Yep, I drilled the 2 bulges on the inside of the piston through to the wrist pin.

[Triesandluth]

I never did that. I didn't have a good enough drill at that point. I can't imagine that causing a problem... 


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[Triesandluth]

This is bugging me now. All the necessary elements to function and no worky. Out of desperation, have you shot any carb cleaner or starting fluid into it?

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[TheAmishSasquatch]

No carb cleaner or starting fluid. I do have some moonshine though Im kinda at a loss myself. I was very concerned that perhaps Ive ruined the portmaps when smoothing the sharp machining edges but I itetally just knocked the sharpness down on the port edges. The piston skirt was already beveled so no work there or piston crown. No cylinder skirt work either. Maybe Z will chime in with a theory (other then my brain is only good for zombie food)

[Triesandluth]

No carb cleaner or starting fluid. I do have some moonshine though Im kinda at a loss myself. I was very concerned that perhaps Ive ruined the portmaps when smoothing the sharp machining edges but I itetally just knocked the sharpness down on the port edges. The piston skirt was already beveled so no work there or piston crown. No cylinder skirt work either. Maybe Z will chime in with a theory (other then my brain is only good for zombie food)

Lol, yeah, he's always hungry. Moonshine might do it if you have the Super hot stuff that's 190 proof.
I can't imagine you messing up the ports. I went to town on my hoca kit, no problems. This kit I just knocked off the sharpness.
Sadly, it's probably something really simple that's evading us. I chased around an issue with random dying to find out I needed to trim my plug wire.
This would be a bit easier to get if you were able to strap on the stock carb. Maybe you could connect the cut bit of the manifold to the old manifold, cover the top of the carb, no cable, and try to get it to start with just the idle screw in a bit more than normal idle. Then you could narrow it down to carb tuning.

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[TheAmishSasquatch]

I just triple checked everything. Between yesterday and today I now have no spark. I even took a brand new Bosch car sparkplug and hooked it up to look for spark. Nothing I have 3 CDI with another on the way. They are good. What could just quit? Ive not touched anything electrical other then disconnecting the autochoke.

[Triesandluth]

I'd start at the cap and work my way back. Including checking that the wire doesn't need to be trimmed. The auto choke wires were secured with no chance of touching? I'm sure that would  possible pop the fuse...
You didn't have to fuss with the stator wires when pulling off the plastics that cover the head?

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