- It only runs decent at more than 3k rpm and even then it's not nearly as powerful as it should be.
- It's miserable to start and the only way I can get it started is with a lot of kicking with the throttle wide open and the gas off because it seems to be flooded.
- It runs even worse with the choke pulled when it is running.
- It runs better with the air filter completely off. I can see it kicking out some gas with the filter off too.
- I've played around with the timing and it doesn't seem to make too much of a difference. I haven't been able to get the bike running well enough to even get it dialed in.
- Idle adjustment mix screw doesn't make any difference.
- Spark plug is also wet.
- I've been on a bike that's been jetted too rich (after another rebuild) and the poor performance feels similar.
It's the same carb described here: http://website.lineone.net/~smallframes/carb.htm
So my guess is that something is screwed up with the carb and it's dumping too much gas into the intake manifold. This is a 19/19 carb which I don't think was stock on a 66 Blue Badge, but is pretty common. The same setup was working pretty well before I converted the bike to 12v ignition and rebuilt the engine. I also dipped and completely cleaned the carb. The same jets are in it that were previously working fine.
Main = 74 (top of the bowl center)
Idle Jet = 42 (screws into the side of the carb)
Starter Jet = 60 (top of the bowl off to the side)
My guess would be that the needle or float were screwed but they both look fine and the float can go high enough to push the needle to close out the hole to stop the gas from coming into the bowl. Also tested that pushing the needle up shuts off the gas flow properly. I'm pretty stumped if anyone's got any ideas. Everything I can see tells me that the float or needle isn't working properly, but everything looks fine.