Hard Starting

[atsalmon]

I just bought my wife a 2003 Blast with less than 1000 miles. The lady that owned it could only get it started by spraying some starting fluid in the carb. I took it to a mechanic and had him rebuild the carb. I have replaced the spark plug (with an original HD plug), and cleaned the air filter (I will probably get a K&N filter). When we try to crank now, it will cough once and if we can't get it to take, then I have to mist the carb with some gas and then if fires right up. After it is warm, it will crank without any extra help. We also replaced the Diodes because they were bad. What else might I need to look at to resolve this issue? Any advice will be greatly appreciated.

Thanks,

 

[ezblast]

First make sure intake coupler is good/prefer new - do this before anything else - cheap and easy to do, then if everything is still the same, sounds like a bad auto enrichner/auto-choke - replace, however, I would also change jetting out to 45/170. It will start easier and run better with this jetting. If you switched over to this jetting first, chances are it would start fine, but you would have to play with the throttle to keep it running the first few minutes. Till warmed up a bit. All this assumes a fresh intake coupler properly assembled.
Enjoy!

Oh yeah - replace the Dunlops with anything else - asap - before you get hurt! New they are a ****** tire, old they are down right dangerous.
EZ

 

[atsalmon]

Any suggestions on a Jet Kit?

Thanks,

 

[ezblast]

Waste of money.
EZ

 

[atsalmon]

But you suggested jetting out to 45/170? Can I purchase just those jets? Would Harley Davidson have those, or will I need to order online?

Many Thanks,

 

[ezblast]

Yes you can buy those jets at any HD shop, any freelance HD shop, and the KLR also runs the same carb, so you can get jets from a Suzuki dealership as well. Or order them from American Sport Bike - they sell them as well - lol
EZ

 

[atsalmon]

Ahhhh, you have to forgive my ignorance <hahaha>. Carbs are one of my weakness' when it comes to maintenance.

Your help is greatly appreciated,

 

[TooFst]

Plug wire?? I work at a shop (autos) and the last 3 diag's that my Mechs. couldn't figure out, we bring in a freelance guy. He replaces wires and we feel dumb.

 

[atsalmon]

OK, I have had the carburetor cleaned and rebuilt, changed out the boot, drained the tank to check the fuel supply valve and strainer, and replaced the air filter. The dang thing still will not crank without me spritzing some gasoline in the carburetor, and it doesn't take a lot. Just one spritz and it fires right up. Am I looking at replacing the automatic choke now?

Thanks,

 

[ezblast]

If they did not change your jetting to 45/170 - it will continue to be hard to start, especially if you are using regular gas, and not using the factory recommended super. The new gasoline with alcohol does not store well, even with stabil, and even a fresh tank of regular will now make it harder to start the bike. If your still not getting enough fuel you have problems. If you can put your hand over the carb mouth and it chokes, then it is not a lean condition, and it still sounds to me like a clogged primary.
EZ

 

[atsalmon]

Thanks, I will get the new jets and see what happens. I appreciate all of your help EZ.

 

[atsalmon]

Well, I finally got the new jets in, and I think it has made a little difference. It's still hard starting, but not as bad. I guess I will just run premium gas in it since that is what it wants anyway.

I do have one more question though. Is it possible to put a manual choke on it? Or is there a different carb with a manual choke that I could replace it with?

Thanks,

 

[wolfo68]

that honestly sounds like a problem I had, and it was that the boot wasn't on properly. I'd get it running and put some soapy water over the boot to check for a leak
otherwise I know the autochoke has been a pita on more than one of these and just needed replaced

 

[ezblast]

Yeah - Replace the boot - they are cheap, and that sounds like your problem. It can develop very miniscule cracks, leak, and do what you are experiencing.
It may not be enrichner/auto choke at all - they are usually very dependable.
EZ

 

[atsalmon]

I have changed the boot, I even bought the super duper boot off of eBay. Other thing that I have changed out are the air fiter, spark plug, gas, drained the tank, cleaned the fuel valve controller, had the carb rebuit, and the jets. Just about anything I can think of that has anything to do with fuel.

 

[wolfo68]

I have the super boot and if it isn't sealed completely you can still have this problem, I only know because that's what mine was

but the soapy water leak test is pretty reliable, after that I'd say it's time to replace the choke

 

[ezblast]

Yuppers, sounds like you have most of it covered on the fuel end, also tighten your grounds, and temporarily eliminate your safeties - kickstand & clutch switch - then if none of that helps, assuming good plug wire and plug, it would be time to replace the enrichner.
EZ