Need diagnosis help. Carbs problem?

I have an 82 xj650 Maxim.

I cleaned the carbs, with help from a friend, and after putting them back together, I was eager to get the bike running. It seems to run fine, just off the fuel in the bowls, but when gas is being fed, fuel leaks out of the air intake side of the carbs. I hooked it up to the engine, but left the rubber boots off of the air intake side just for testing. Thank goodness I did or there would be fuel in the air box. It doesn't seem like any of the gaskets leak, it just comes out the air intake side.

Floats seem to be the obvious culprit, but I want more advice before I buy a rebuild kit for the carbs. The bike ran before, so I made no adjustments to the float levels. I also do not have a service manual yet, due to cash constraints, but I will get one soon. I'm thinking I might need one for this problem, though..

Any advice?

Thanks!

 

there is a adjustment to stop the floats from going down too far, they can go down so far they get jammed down there.
the tab that the needle valve rests on could have a scratch on it, jamming the needle valve.
you didn't put them in upside down did you?
the book doesn't have much in it about carbs but it's good to have one

 

If the fuel is coming out of the intake it is obvious that gas is overflowing the bowls, you have two options since none were addressed when you cleaned the carbs:

The needles need to be replaced because they are not closing properly and set the float levels to specs. I would save me time and frustration of doing half jobs multiple times and just cover everything at once. There are different rebuilt kits that you can get from Len (chacal) depending on how much you need to replace or has been done in the past.

If you already cleaned everything in there (jets, emulsion tube, etc) you will be a carbivore in no time.

have fun and good luck

 

Should've wet set the floats before refitting IMO, just because the bike ran doesn't mean they were right (after all, you said it runs now, even with them pissing out). Rookie mistake. Sorry, but it's true & stems from either not bothering to read the guides on here or more likely, getting too bored before getting to the bit about float setting. Those guides are looooong, but with good reason

Sorry, carbs off & do the whole job is the diagnosis from this bloke

 

+1 on the float levels being off. Also, The bike wont run right without being connected to the airbox. Have you seen all the pod filter threads? Dont worry though, I made the same mistake you did. I know those carbs inside and out now 8)

 

+1 again on the float levels. The link to the process is in my signature line...

 

After you get the float levels properly set, but BEFORE you return the carbs to the bike, do an accurate bench sync.

Then, once your VALVES ARE IN SPEC, you'll be able to do your running vac sync, with the YICS blocked.

But you will need to thoroughly clean the carbs first, and replace the tiny o-rings on the pilot screws. DO NOT fully submerge the carbs in any sort of cleaner unless you plan to break the rack and replace the throttle shaft seals (which may or may not be necessary, no sense forcing the issue.)

Then we need to talk brakes. It is 30 years old, after all.

READ THESE: http://xjbikes.com/Forums/viewtopic/t=15874.html and http://xjbikes.com/Forums/viewtopic/t=41400.html

You're going to need that service manual. And budget about $600 maybe $800 if you really want to ride this bike and have it be safe and reliable.

 

Welcome to XJ Bikes robut! Most all of us have been at the "low on funds, high on enthusiasm" program. Fortunately there are some things you can do that don't cost much and you can hear the engine purrrr. In no way am I suggesting riding without following the aforementioned safety threads listed above. The following links (with diagrams) will give you stuff that needs to be done and is a start.
I made a Yamaha folder in my Favorites and Bookmarked the following for easy reference.

Carb Cleaning>>>
http://xjbikes.com/Forums/viewtopic/t=2 ... rt=30.html

Carbs need to Clunk>>>
http://xjbikes.com/Forums/viewtopic/t=1 ... clunk.html

Setting float heights dry>>>
http://xjbikes.com/Forums/viewtopic/t=9 ... art=0.html

Bench-synch your carbs>>>
http://xjbikes.com/Forums/viewtopic/t=6366/

How-To Links>>>
http://xjbikes.com/Forums/viewtopic/t=8588.html

 

You guys are awesome!