Join Date: Jan 2017
Location: St. Louis MO
Thanked 16 Times in 12 Posts
Worked on the 2004 carb today.
The last two days here have been pretty nice temp wise. Got close to 50 both days, so I took it apart again and while I didn't yet buy a rejet kit, I did drill out the plug on the carb blocking the fuel/air adjustment screw. I imagine they are all alike, mine had a tiny hole in the center of the brass plug, so rather then go the route of drilling a 5/32 hole and then messing with pulling the remainder out with a screw as the kit instructions give you, I just picked a drill the size of the plug, and after enlarging the pilot hole a bit to keep the larger drill on center I drilled it out leaving just a paper thin ring. It popped right out.
5 1/4 turns out takes care of the lean running and starting problem without the needle or the larger jet. So in case anyone is wondering yes you can make the bike run fine with aftermarket pipes (I have baffled Cobra Streetrods) by simply adjusting the rich/lean screw.
I took it out on the road and made a couple of adjustments as I rode to get it just right. You need a long thin small straight blade (about 6 in.) to get past the valve on the left side, and a good light to see up under the tank. Starts up a lot better and you can put the choke in much quicker and it keeps running fine. I'm a happy camper.