Thanks BrianZ! The needle jet removal trick is a great idea. We have a bearing supplier in town that stocks or can get anything. Next time I tear it down, I'll go that route. I had completely forgotten about the circlip too. I hope that changing back to gearsaver oil fixes my problem. Now, I have pa...

Finally! I was able to work on the bike this week after being under the weather for weeks and backed up at work. So, I think the plug fouling is solved! The carb parts came but did not change the main needle jet. It looked new compared to the new one I ordered. So I checked the float setting and re-...

My new needle jet should arrive by mid week. I disassembled the carb today and the needle jet doesn't really look worn even though I don't have one to compare yet. So I'm thinking of plan B. I have a few more items to get to make my leak tester. I did find black oil in the exhaust port when I remove...

All really good points!! My confidence level is now 300% better. Looks like I have my work cut out for me this weekend. Just picked up hardware to build leak tester. I have now learned a lot from your posts and greatly appreciate it! I will post everything I find out as soon as I can.
--Champ

Thanks everyone for the great advise. I'm purchasing hardware to perform the leak down test this weekend. I've built the same kind of rig for my turbo Ford for intake pressure testing so I have most of the parts. I like the idea of leak testing after engine rebuilds but never thought of it before. I...

Russell - Thanks for the tips! Do you remove the needle jet by tapping it from the bottom (bowl side) so that it exits through the top? Or the other direction?

Thanks Dale! I'll post results. It's hard to believe that the new seals will go bad after 40 or so hours but I guess it can happen. Arizona - I think mine has to be tapped out as Laurie describes because the needle jet body is flush with the hole in the bottom of the body. Therefore, there is nothin...

Good point Dale. I figure if the needle jet is not worn, that's my next direction. I suppose I can search here for the leak down test?

The engine is running rich and fouling plugs about every 15 minutes. The plug is carbon fouled and I have re-jetted the main LEAN to the point of cutting off at wide open throttle but still no difference in fouling. The idle mixture is also as lean as I can get it. It cranks first kick and idles fin...

I'm new to the group. So my attempts to search for this subject has failed. How do you correctly remove and replace the worn needle jet from the VM20 carb that's on the 100? Thanks!