1986-2008 Harley XL-XLH Sportster Fuel System Troubleshooting for Carbureted Models 


1986-2008 XL/XLH 883, 1100 & 1200 Carburetor Troubleshooting

Need to fix your Harley Davidson Sportster Chopper? Visit the Home page to get the complete factory service manual  for your 1986-2008 Sportster motorcycle and get it delivered to your computer in just seconds!


 
SPORTSTER MODELS

1986-2003 Harley Davidson Sportster Motorcycle Service Reapir Manual for: XL & XLH models, including XLH883, XL883R, XLH1100, XL1200, XLH1200 (883/1100/1200), Custom, Sportster Deluxe, Hugger, Custom and Sport model years 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 and 2003.
 
2005 H-D Sportster XL Service Manual & 2005 H-D Sportster XL Electrical Diagnostics Manual for: 2005 Harley-Davidson XL 1200C Sportster 1200 Custom, 2005 Harley-Davidson XL 1200R Sportster 1200 Roadster, 2005 Harley-Davidson XL 883C Sportster 883 Custom, 2005 Harley-Davidson XL 883 Sportster 883, 2005 Harley-Davidson XL Sportster 883L, 2005 Harley-Davidson XL883R Sportster (XL883, XL883L, 883R, XL883C, XL1200C, XL1200R, XL1200).
 
2006 Harley-Davidson Sportster Motorcycle Factory Service Manual for: 2006 XL 883 Sportster, 2006 XL883, 2006 XL 883L 883 Low, 2006 XL 883C Sportster 883C Custom , XL 883R Sportster 883R, XL 1200C Sportster 1200 Custom, XL 1200R Sportster 1200 Roadster, XL 1200L Sportster 1200 Low.
 
2007 H-D Sportster XL Service Manual & 2007 Harley Davidson Electrical Diagnostics Manual for Harley Models: 2007 XL SPORTSTER 883 (XL883), 2007 XL SPORTSTER 883L (883-L), 2007 XL SPORTSTER 883R (883-R), 2007 XL SPORTSTER 1200L (1200-L), 2007 XL SPORTSTER 1200 N (1200N), 2007 XL SPORTSTER 1200 R (1200R), 2007 XL SPORTSTER 883C/XL 1200C, 2007 XL SPORTSTER 50 motorcycles.
 
2008 Harley Davidson Sportster Motorcycle Factory Service Manual for: 2008 XL 883 Sportster, 2008 XL 883C Sportster, 2008 XL 883L Sportster, XL 1200L Sportster, XL 1200R Sportster, XL 1200N Sportster, Harley Davidson XL 1200C Sportster, XL 1200C Sportster Custom 105th Anniversary Edition. 08 Harley Custom, 08 Harley Nightster, 08 Roadster, Sportster Low.

Note: The information below should not be used as a reference as this is only a sample of information typicaly found in a service manual. For complete specifications for your year and model Sportster carburetor download the correct manual for your bike from the DOWNLOAD CENTER . Feel free to preview a sample to get an idea of what it looks like. Stop the guess work on your carburetor and get a manual!

Each Manual contains a carburetor troubleshooting section helping you identify causes to your carburetor problems and providing step-by-step procedures to service and repair your sportster carburetor. If your experiencing overflow, poor idling, poor fuel economy, poor acceleration, hard starting, hesitation, poor performance on the road, poor high speed performance than refer to the service manual provided to help you troubleshoot every aspect of your sportster carburetor.

Carburetor Problems

Damaged float bowl O-ring.
Damaged or leaking float assembly.
Particle contamination in fuel inlet fitting cavity.
Worn or dirty inlet valve or seat.
Improper fuel level in float bowl.
Tighten screws.
Replace O-ring.
Replace float assembly.
Clean and clear cavity and fuel supply tract.
Clean or replace valve and clean seat.
Adjust float tab for correct fuel level.
Idle speed improperly adjusted.
Inlet system air leak (faster idling).
Loose low speed jet.
Contaminated or plugged low speed system.
Adjusting operating idle speed.
Tighten jet.
Excessive use of enrichener system.
Enrichener valve not seated or leaking.
Dirty air cleaner element.
Restricted fuel tank vent system.
High speed riding style.
Idle speed improperly adjusted.
Loose jets.
Fuel level too high.
Plugged or restricted bowl vent.
Worn or damaged needle or needle jet.
Vacuum piston assembly malfunction.
Plugged air jets or passages.
Excessive accelerator pump output.
Modify riding habits.
Adjust operating idle speed.
Tighten jets.
Replace needle or needle jet.
Clean and clear passages.
Check and clean accelerator pump bypass orifice.
Throttle cables misaligned.
Inlet system air leak.
Restricted fuel tank vent system.
Restricted fuel supply passages.
Plugged bowl vent or overflow.
Enrichener valve not seated or leaking
.
Worn or damaged needle or needle jet.
Vacuum piston malfunction.
Plugged jets or passages.
Fuel level (float chamber) too low.
Accelerator pump leaking or no output.
Adjust throttle cables.
Correct and clear restriction.
Adjust float level.
Enrichener system plugged, not properly functioning or improperly operated.
Inlet system air leak.
Restricted fuel supply.
Fuel overflow.
Plugged slow jet or passages.
Clean, adjust, or replace; or read Service Manual.
Correct as required.
Check fuel supply and/or passages. Verify that vacuum operated fuel valve is functional.
Clean and clear jet or passages.
Idle speed improperly adjusted.
Inlet system air leak.
Restricted fuel tank vent system.
Dirty or damaged air cleaner element.
Enrichener valve not seated or leaking.
Restricted fuel supply tract.
Plugged bowl vent or overflow.
Loose or plugged fuel and air jets or passages.
Worn or damaged needle or needle jet.
Vacuum piston assembly malfunction.
Accelerator pump inoperative.
Adjust operating idle speed.
Correct restricted hose. Replace vapor valve.
Clean or replace.
Adjust, clean or replace.
Correct and clear restriction.
Clean and clear passages.
Clean, clear and correct as required.
Inlet system air leak.
Enrichener valve not seated or leaking.
Restricted fuel tank vent system.
Restricted fuel supply tract.
Dirty or damaged air cleaner element.
Plugged bowl, vent or overflow.
Worn or damaged needle or needle jet.
Vacuum piston assembly malfunction.
Loose or plugged main jets or passages.
Improper fuel level.
Accelerator pump inoperative.
Clean or replace.
Adjust, clean or replace.
Correct restricted hose. Replace vapor valve.
Correct and clean restriction.
Clean or replace.
Clean and clear passages.
Adjust float level.
Enrichener valve open, not seated or leaking.
Piston atmosphere vent blocked.
Diaphragm cap loose, damaged or leaking.
Spring binding.
Diaphragm pinched at lip groove.
Torn diaphragm.
Correct or replace spring.
Reposition diaphragm lip.
Replace piston diaphragm assembly.
  
2. Screw and washer (3)
3. Spring
4. Vacuum piston
5. Spring seat
6. Jet needle
7. Vacuum hose
8. Needle jet
9. Needle jet holder
10. Main jet
11. Slow jet
12. 4-sided Fuel valve with clip
13. Pin
14. Float
15. O-ring
16. O-ring
17. Screw and washer (4)
18. Cable guide
19. Starter cap
20. Cable sealing cap
21. Enrichener valve
22. Spring
23. Bracket, throttle cable
24. Screw (throttle cable bracket)
25. Screw (throttle cable bracket)
26. Screw (idle speed adjust)
27. Spring
28. Collar
29. Seal ring
30. Manifold
31. Flange
32. Seal, intake manifold (2)
33. Lever
34. Float bowl
35. E-clip
36. Accelerator pump nozzle
 
Tags: Harley Davidson Sportster Carburetor 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, Carb, Overhaul, Overhaul, Rebuild Kit, Part, Parts, Aftermarket Parts, Performance Parts, Where is the, How Do you fix, Located & Locations, What is the

sportster electronic fuel gauge 
online repair manuals for 2002 883 sportster 
how to replace a choke cable for 2000 sportster 
2000 harley sportster manual Carb Float bowl
1989 harley sportster Screw (idle speed adjust)
carburetor adjustments for a h-d model xl 1000 
sportster 883 deluxe 1986 enrichener located
harley davidson 86 sportster direction fuel lines 
2000 harley sportster Enrichener 
removing 1996 harley davidson sportster carburetor (Carb)
harley sportster xlh 1998 Throttle Control Cable
fuel shut off vavle harley 883 
how to clean carbs on 1991 harley 883 sportster
service manual for 1992 harley sportster
Idle Speed Set Screw for 1991 harley davidson sportster 
motorcycle repair manual 
harley fuel mixture adjustment procedure 08 sportster 
2000 harley davidson 1200 custom system troubleshooting 
2006 harley davidson sportster 883 fuel enrichment circuit
1100 sportster float operated inlet valve
carburetor for harley sportster 1995
2006 harley sportster fuel filter
harley sportster 2008 883 xl fuel pump