Harley Davidson (1970 to 1978) Sportster XL/XLH/XLCH/XLT-1000. Service manual — page 9

ASSEMBLING CARBURETOR (Figure 3-76)

Throttle Body

1. Position throttle return spring (29) on throttle shaft. Slide throttle shaft and lever (28) into seal retainer (31) and seal (33). Insert shaft in throttle shaft hole from side shown. Guide shaft into hole on opposite side of bore and press seal and retainer firmly against shaft hole boss

2. Slide seal (32) and retainer (30) over end of throttle shaft and seat firmly against shaft hole boss.

3. Rotate throttle shaft until flat center section faces toward manifold opening. Install throttle disc (26) loosely with screws (27). Snap disc open and shut several times to center disc, and then tighten screws holding the throttle disc seated in the casting. Be sure the disc is held tightly closed.

4. Insert seal (24) and retainer washer (23) in choke shaft hole. Use a small punch to stake retainer in place.

5. Slide choke shaft and lever (22) through retainer and seal and seat shaft in hole in opposite side of air intake. Install plunger and spring (22A and 22B) at this time.

6. Rotate choke shaft until flat center section faces toward intake opening. Install choke disc (20) loosely with screws (21). Snap disc open and shut, and then tighten screws using the same procedure as for throttle.

7. If choke cup plug (25) was removed, install new plug in choke shaft hole on opposite side of throttle body.

8 Place throttle body with fuel bowl side up and install bowl to body gasket (15).

9. Insert fuel valve assembly (14) in fuel valve seat. Assemble float spring (13) and float (12) and install float pin (11). Be sure that fuel valve clip is attached to the float tab. If necessary, bend clip to provide minimum clearance with tab (approximately .010 in.).

10. With the carburetor inverted (inlet needle seated), bottom surface of float should be 3/16 in. from gasket surface at point opposite hinge. A 3/16 in. drill can be used as a gauge as shown in Figure 3-77. It adjustment is required, use long nosed pliers to bend the tab that contacts the fuel valve. Be careful to avoid damage to the fuel valve or seat

11. Install throttle stop screw (18) and spring (19). Adjust screw to open throttle slightly but not far enough to uncover the No. 2 idle discharge hole.

12. Install idle mixture needle (16) and spring (17). Screw needle IN until it seats lightly against the No. 1 idle discharge hole, then back it out 1 -1 /2 turns as a preliminary idle adjustment.

Bowl

1. Carefully guide cup of accelerating pump (3) into pump well. Seat accelerating pump boot around top of accelerating pump boss.

2. Assemble washer (7) on main jet and discharge tube (6) and assemble O-ring (8) in groove near end of discharge tube.

3. Hold carburetor inverted (with float up) and rotate the long end of the spring upward so that it is against the float.