Here is where I am, 1989 Sportster CV carb with new CVP inlet added last year. Last year the bike started gas poured out the carb and overflow i took it off tinkered with it, worked fine all summer.

Sat over the winter, when gas is on from the petcock it overflows the overflow. (usually turn it off before it comes out the top) runs fine when idle and i can drive it as long as i manually give it gas by turning the petcock on and off. lol

my initial thought is probably yours, rebuild kit and needle is damaged or stuck. However for the twist... I notice the vacuum is grounded but isnt connected to battery. I can see the wire and i know it is suppose to go to the power.

Question is... does that vacuum matter enough to let it overflow? or is it just as simple as probably the needle and float?

 

FYI, vacuum is a rubber hose that air passes through, are you referring to the VOES sensor? In any case, that won't cause the bowl to overflow.

Yes, it's as simple as the needle, needle seat or float. Make sure the float doesn't have a leak, it needs to float not sink. Make sure the float is adjusted per the Service Manual. Replace the needle and make sure the carb bowl is clean. If there's trash in the bowl, check the fuel tank filter.

 

What Charley said concerning the carb, and I wouldn’t be surprised if your fuel tank is full of crud and has a damaged fuel screen... causing issues with your carb. It's a 25 year old bike, so consider pulling the tank, remove the petcock / screen filter, then thoroughly wash the tank out with soapy water.

 

New update. Rebuilt carb with kit from jp cycles. 1 wholly crap it had everything. 2 super easy.

Now I have the opposite problem. Lol no gas at all! I have even tested the carb on float bowl off and gas connected. Drop the float gas comes through. Put it all back together no gas comes through at all.

I am believing that the float arm that holds the needle needs to be bent a hair to allow the new valve to flow. My fear is doing this properly.

@run1fsr any ides how much gas should flow seems real clean and the entire bike had been gone through many times.

The voes sensor is attached but the vacuum hose goes to it. Didn't know if it runs with out power or not. Help? Need to ride!!!

 

the float is prolly bent to one side and hitting the float bowl...also did you set the float height???the setting should be in the kit directions

 

Your VOES should have a wire from the ignition module and the other wire goes to ground. the vacuum hose goes from the VOES to fitting on top of carb.

John

 

True on the voes wire that should be going to the ignition module isn't connected. Apparently hasn't been for some time so I'm guessing the carb doesn't need it.

Float isn't bent and I can see very clearly that it drops down in the bowl whole installing it. However no directions other than my book on adjustment.

Thing is I can see that the float doesn't go up when installing the bowl. I can see that the valve seats and when I push the float up it moves the spring in. But it must be up to much still. Book says at a 15-20% angle it should be flat against the carb. Seems like a lot of bending.

 

You have the round or square shaped float ?

 

Yeah so weird thing about my 89 is it's the deluxe which I'm guessing got me some later model year parts. Like my oil drain is that of 90+

Or previous owner messed with the float before. Either way I have flat floats not the round ones I should have.

 

Update: got it working about as good as I can. No overflow no stall just needed to adjust the float to the level in the book. Which I have to say I thought was crazy far but can't complain so far.