Carb rebuild woes

[Frankencelery]

I've finally gotten around to rebuilding the carb on my KLT110. I managed to destroy one carb, but I had another spare, so I used that one. For the first time ever, it idles, but you can't actually ride it! As soon as you rev it up, it chokes and sputters. If you rev it up in neutral, it revs fine, but immediately drops off. If you stay on the gas, it will die. Let off, and it comes back to a normal idle.

I can't help but think it must be the float level, but I thought I'd come in here and ask first. Taking the bowl off after disconnecting the gas tank, it looks full, so I'm doubting myself. Any ideas?

[1984 honda 200s]

sounds to me like your throttle needle is mis adjusted, id either drop it one notch or raise it one notch..see what it does then..

[RubberSalt]

It's currently lean. It doesn't take much to rev an engine without a load.

Get your pilot jet tuned in right, probably 2 turns out on the fuel screw, that gets you from no throttle to 1/4. From there work on your needle position, Stick the clip in the middle and work from there. The needle clip effects 1/4-3/4 throttle, and the main jet from 1/2 to wide open.

I'm guessing your on a stock 110 with a stock carb and jets. otherwise, tune in the pilot, then the main then the needle

[Frankencelery]

Funny thing about this rebuild that made me uneasy. I replaced the main needle seat, and the new one sticks up a lot higher inside the carb than the old one did. I can't help but wonder if it's not the right application. The carb kit was supposed to be for the KLT110. That housing sticking up into the throttle bore seems like it would be just like lowering the needle, which would fit your description of it being lean.

[Frankencelery]

Ok, so I got out there tonight and moved the needle up all the way...no difference. It is definitely starving anywhere from 1/2 to WOT, which as I thought about it, has nothing to do with the needle. So I revved it up until it stalled, and quickly pulled the fuel line. Took the bowl off and it's full of gas, so it's not the float level. The only thing left is the main jet. So I pulled the main jet and looked for a number. The original was #102. This one has no markings on it at all, but eyeballing it, it is visibly smaller than the #102. So I just put my old main jet back in and it runs great!

The carb kit is being sold by a seller on Ebay called Wincycles. I sent him a message to let him know. Might have just been the wrong jet in my package, or maybe it's the wrong jet for the KLT110, I'm not sure. Just FYI for anyone who is thinking of buying this kit.

[Dirtcrasher]

Some of the kits are good, some are junk. The moose kit I got had an airscrew with the wrong pitch. I believe it was K and L that made the good kit, but I'd have to double check.

[haywiremechanic]

I recently bought a K & L carb kit on ebay for an ATC185s. It was "Made in Japan". Good quality and the parts fit and worked. I'd buy another K&L kit anytime.

It's always a good idea to re-use your OEM jets if possible when rebuilding a carb, in my experience. The inlet needle valve is the part that wears and usually needs replacement.