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  1. #1

    Unhappy Fishin for answers!!!

    Hi guys. Needing some help BIGTIME! Customer brings me an "03" Sportster LE (951 carb)...he's been tinkering with for months. I check compression...it's wasted...so I rebuild topend with 88.5 wiseco's ( bores have .006" clear) I also rebuilt the carbs ( he was tinkerin ) and I gave it A tad more fuel (1/4 mag, 1/2 pto)...fires up sounds perfect. Run the boat & it will only pull 5-5500rpm.Plugs are nice brown...so I lean em about 1/16. Scuffed the crap out of the pistons. When I tore it down...lots of fuel in the crankcase...runs fine out of the water. I have the engine on the bench & i'm gonna go through the bottom end for 100% sealing.
    I've rebuilt quite A few of these in the past...but have been out of the loop for about 8 years from back surgery...things have changed A little!! Throw me some bones...I'd appreciate it bigtime! Gonna be A garage weekend.

    THANKS


  2. #2
    flyin' the friendly skies airbornexp's Avatar
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    sounds like a carb problem, leaky needle and seats...did you rebuild the carbs or just clean the screens and such?

  3. #3
    Rebuilt em completely! They seem very responsive...just no power & won't pull over 5500. This thing is giving me A major head/back ache.
    Started out as A simple top end rebuild...turned into much more.

    Never much liked Sea-Doo...Kawi's never gave me A lick of trouble! lol

    Thanks for the response...much appreciated!!

  4. #4
    Work Harder, Millions on Wellfare Depend On Us! ultramaxracing05's Avatar
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    have you checked the rave valves?
    or maybe perhaps the owner messed with the water pressure regulator

  5. #5
    did you clearance the raves?

  6. #6
    Tool Bag water worx's Avatar
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    The throttle cable has a switch built into it that advances the timing...that needs to be checked & the raves are operated by a solenoid & might not be opening.

  7. #7
    Where is this switch? I looked at the throttle handle assy...just A neutral switch. Electrical part of the rave solenoid tests ok...raves are perfect...and WR is new ( but he has had it apart)New crankseals.
    Engine seems to run fine...even leaned out the carbs to no avail! Almost seems to be starving for fuel?
    Drop the throttle and winds up to 6000...and thats it! Maybe I messed up in the carbs? (I really have rebuilt hundreds of these but noones perfect!) Broken reed?

    Not much more to this engine!! Really getting to me...

  8. #8
    Work Harder, Millions on Wellfare Depend On Us! ultramaxracing05's Avatar
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    its not a switch follow your throttle cable and you will find the connection where 3 wires are sticking out of the cable
    its called a TPS sensor

  9. #9
    Mtuned's Avatar
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    Im Assuming oil pump is bled, there is no air in the lines?

    did you premix the first tank of gas for break in?

    What settings DID you run on the carbs? Did you replace the needle seat/ spring, and jets?

    Are you sure there OEM jets?

    If it seemed to ride ok, and it scored them again, im guessing lack of oil. If you got them lean enough to burn em, id have to guess you would notice the issue before death!

  10. #10
    Mtuned's Avatar
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    Also what color fuel lines?

    Could be a fuel delivery issue going to carbs since you said you rebuilt the carbs!

    Did you measure cranking compression after rebuild?

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