ES2 carb problem

Fuel level too low.Wrong parts fitted . Cut a new slot on the float needle (use a hacksaw blade) set level about i/8" below point at which the carb floods.

Check for blockages in the carburettor, refurbished does not mean it doesn't have bits of swarf caught somewhere, missed by the assembler. If it is perfectly clean, then check the settings.First thing you need to do is establish if the fuel level is the problem. Remove the small blanking plugscrew on the side of the bowl banjo and pressthe end of a length of clear plastic tubing over it. Run the tube up wards against the carburettor body and turn on the petrol. Observe how high the fuel rises in the tube, the level should be just below the idle mixture screw with the machine uprighton level ground. Adjustment is made by changing the large union nut to either a longer or shorter one. From memory, there are 4 different lengths.

If you raise the fuel level you may have to shorten the tickler ,try it with the tickler removed. You may have pilot drilling blockage and you can knock out the jet block to check the tiny pilot drillings,renew the paper gasket on the block, also check the by pass drilling in the carb body.

Hi Ben, the nut I refer to is the big one that screws onto the bottom of the carburettor body, to which the fuelbowl banjo is bolted to underneath. There are different lengths (heights), so by getting a shorter or longer one, it will lift the bowl higheror lower in relation to the main jet block, which is also raising or lowering the fuel level.

One easy check to see if the fuel level is too low in relation to the needle jet is, while engine is running, lean the bike over to the right. This will raise the level in the mixing chamber and the engine will idle smoother with no spitting back through the carb. Lean to the left, as on the side stand, and the engine will falter, spit back and have an irregular idle, because the level has now been lowered in the mixing chamber.

OR, while riding, reach down and depress the tickler, this will raise the fuel leveland once again, if the levelwas too low, this will smooth out the engine.

Just read your original post again, and the ignition timing is 5/8"B.T.D.C. fully advanced, not 3/8"as you state.

If when you have got it to run it needs the mixture screw nearly all the way in its likely that the pilot fuel supply is a bit too small. Those tiny drillings in the jet block may need re-sizing ,its possible to do it with some very small drill bits that can be found on E-Bay,just go very slowly as new jet blocks are not that easy to come by. A micrometer is usefull.