2006 Harley-Davidson XL 883 Sportster 883, 2006 Harley-Davidson XL 883L Sportster 883 Low, 2006 Harley, Davidson XL 883C Sportster 883C Custom , 2006 Harley-Davidson XL 883R Sportster 883R, 2006 Harley-Davidson XL 1200C Sportster 1200 Custom, 2006 Harley-Davidson XL 1200R Sportster 1200 Roadster, 2006 Harley-Davidson XL 1200L Sportster 1200 Low.
This service manual covers all the following Sportster Models: XL883, XL1200, XL883L, XL883C, XL883R, XL1200, XL1200L, XL1200C, XL1200R Including Domestic and International Models.
See Figure 4-2. The carburetor is a constant-velocity, gravityfed
type with a float-operated inlet valve, a variable venturi, a
throttle stop screw (for idle speed adjustment) and a fuel
enrichment system (for starting).
Idle and transfer ports provide a balanced fuel mixture during
the transition period from stop to mid-range. A vacuum piston
controls venturi opening.
The carburetor is specifically designed to control exhaust
emissions. All jets are fixed. The idle mixture has been preset
at the factory. The idle mixture screw is recessed in the
carburetor casting. The opening is sealed with a plug
because it is intended that the idle mixture be non-adjustable.
Adjusting mixture setting by procedures other than specified
in this section may be in violation of local regulations.
This system partially compensates for changes in the mixture
that are normally caused by changes in altitude. Because
atmospheric pressures drop as altitude increases, the pressure
difference in the upper and lower chambers is reduced;
this results in less fuel being delivered to the engine, thereby
maintaining the correct air/fuel ratio for better engine performance
and reduced exhaust emissions.
The carburetor is equipped with an accelerator pump. The
accelerator pump system uses sudden throttle openings
(rapid accelerations) to quickly inject raw fuel into the carburetor
venturi; this provides extra fuel for smooth acceleration.
1. See Figure 4-3. Place carburetor on a flat, clean surface
on engine manifold side. This is the “base.” Tilt carburetor
counterclockwise 15 to 20 degrees from base until float
Vacuum Piston Chamber
1. See Figure 4-4. Remove screws (11, 13) and throttle
cable bracket (12).
2. Remove three screws (1). Remove top cover (2) and
3. Lift out vacuum piston (6) with needle jet (5) and spring
seat (4). Remove loose parts from vacuum piston.
1. See Figure 4-4. Remove four screws (27). Remove float
chamber assembly (26).
2. Remove pin (53), float (50) and fuel inlet valve assembly
3. Unscrew main jet (28) and needle jet holder (29). Needle
jet (30) is free to be removed from bottom end of passage.
4. Insert thin-bladed screwdriver into slow jet passage to
remove slow jet (55).
1. See Figure 4-4. Remove three screws with lock washers
(24), accelerator pump housing (23), spring (22) and diaphragm
2. Remove O-ring (25) from housing.
Carburetor Fuel Overflow/Drain Hose
See Figure 4-4. On non-California models, route fuel overflow/
drain hose (19) from the carburetor fuel overflow fitting
downward and rearward through the space between the
engine rear cylinder and the rear cylinder push rod covers
(intake and exhaust), and then downward through the space
between the engine crankcase and the gear cover.
On all California models, route the fuel overflow/drain (vent)
hose from the carburetor fuel overflow fitting, under the carburetor
float chamber, to a plastic fitting on the inboard side of
the air cleaner backplate. Connect canister purge hose onto
fitting on carburetor body. See 4.9 EVAPORATIVE EMISSIONS
CONTROL–CA MODELS and INSTALLATION under
4.6 AIR CLEANER.