INSTRUCTIONS - Harley
Contents
1. 6 of 9 MOTOR Service Parts Gasket Shown for Illustration Purposes Only Not Included Kit Number 27454 01 Item Description Carb Assembly Adapter O ring Main jet 155 not shown Main jet 165 not shown ak WOND J01837 Gasket Shown for Illustration Purposes Only Not Included Screws From Screamin Eagle Air Cleaner Kit Part Number 29041 88B Part Number not sold 27156 98 27154 98 27910 98 27914 98 Kit No 27454 01 Date 6 01 42mm Flatslide Carb Kit i03918 i03952 Buell Fitment Use 1 4 20x1 1 4 inch or stock original Backplate Assembly Screws Do Not use screws from Race Air Cleaner Kits Part Numbers 91421 99Y and 29461 96Y Item Description Part Number 6 7 8 9 Hose clamp 2 not shown not sold Cable tie 3 not shown 27753 98 Washer retention not shown 11192 Hose vacuum 3 16x5 1 4 inch not shown not sold 7 of 9 Kit No 29565 98 Date 6 01 101749 tiff 1 2 A _ Y NOTE See next page for index identification and description Service Parts have a Harley Davidson Part No listed J01837 8 of 9 SMOTOR Service Parts ltem 1 2 3 4 5 6 Description Part No Screw top cover flat head Screw top cover Top cover Gasket top cover 27768 98 E ring jet needle 27761 98 Washer needle clip 27760 98 Jet needle 4 sizes available Lever throttle valve E ring2. Packing link lever Pin link lever Throttle valve Screw needle retaining clip Clip needle retainer Sealing ring throttle valve Seal throttle valve Pulley cable bracket E ring cable bracket Bracket ass y cable Bolt Spacer Plate lock tab Screw Guide holder starter Spring starter plunger Starter plunger Body ass y bearing and spigot N A Seal spigot body Ring Steel Lever accelerator pump Pin throttle lever Lever throttle Spring accelerator pump adjuster Screw accelerator pump adjuster Spring accelerator pump return Mixing body ass y N A Packing shaft plastic Adjusting screw accelerator pump O ring accelerator pump screw Plate lock tab for shaft Pin throttle stop lever Lever throttle stop Adjusting screw throttle Item 44 NOTE Kit No 27454 01 Date 6 01 42mm Carb Rebuild kit Description Part No Nut throttle stop Spring throttle return Shaft throttle Plate fuel joint retainer Screw fuel joint retainer Screw pilot air adjusting Spring pilot air screw Washer pilot air screw O ring pilot air screw Fuel joint O ring fuel joint Packing idle adjuster Washer idle adjuster Steel Spring idle adjuster Ring idle adjuster Brass Idle adjuster ass y Long Idle adjuster screw Short Air jet Blank Needle jet 723 Series Nozzle accelerator pump O ring accelerator pump Pilot jet Extender main jet Main jet O ring needle valve 2775
3. installation 1 Refer to Cable Routing Buell Models on Page 5 and perform Step 1 2 Screw the cable adjusters together to make them as short as possible 3 See Figure 6 Remove throttle cable clamps and dis card 4 Connect the close cable first then install the open cable See Figure 4 for close up of cable installation 5 Connect V O E S hose NOTE Before inserting the carburetor into the stock manifold check the condition of the rubber seal If the seal is damaged it must be replaced to prevent air leakage The fit between the carburetor and the seal ring is tight For ease of installation it is recommended that the mating surfaces carburetor body and seal ring be lubricated prior to assembly to reduce sur face friction Use liquid dish soap or tire mounting lube for this purpose 6 Lubricate only the inside surface of seal ring that will be in contact with the carburetor Also apply a light coat of lubricant to the spigot of the carburetor body Push car buretor into seal ring 7 Connect fuel hose to carburetor using new clamp from kit 8 Refer to Figure 4 on Page 3 Refer to the applicable Buell Service Manual and adjust throttle cables following the instructions given Adjust throttle cable so throttle valve slide opens fully Lever stop screw should touch carb body at wide open throttle To adjust lever stop screw loosen jam nut and turn screw in clockwise or out counterclockwise r
4. instructions in applicable Service Manual and fin ish removing carburetor 10 Remove choke enrichener cable from the carburetor and discard carburetor Choke The carb in this kit uses stock choke cable and stock black plastic nut Obtain the new carburetor from kit Remove black plastic nut from kit carburetor and discard it Remove spring and plunger from carburetor kit and install them on the stock choke cable and attach to kit carb Discard stock choke spring and plunger Do not over tighten the plastic nut Choke adjustment procedures are covered at the end of these instructions 11 On XL models perform hose modifications described on the following page NOTE If your installation is for Buell proceed to Page 4 1of9 XL Models Only Fuel and Vacuum Hose Modification NOTE On XL Models the Fuel hose and Vacuum Hose must be modified prior to installing to the new carburetor Perform the following procedures 1 See Figure 1 Locate and remove the fuel hose from the fuel petcock Lay the hose on a flat surface and trim 1 2 inch to 5 8 inch of the hose from the end of the bend 2 Obtain one of the Hose Clamps from kit and using clamp reinstall end of hose trimmed in previous Step to fuel petcock Tighten securely 3 See Figure 2 Note that Figure 2 represents the current Vacuum hose configuration The heat shield is installed to Fuel Petcock hose the short hose routes to V O E S and the long hose routes to car
5. lt MOTOR2 HARLEY DAVIDSON ND J01837 INSTRUCTIONS REV 6 8 01 Kit Number 27454 01 S E FLATSLIDE CARB KIT FOR SPORTSTER AND BUELL General This kit is designed for use on 1995 and later XL 1200 s and all Twin Cylinder Carbureted Buells NOTE On XL Models you must use SCREAMIN EAGLE Air Cleaner Kit Part Number 29041 88B with this carbure tor On Buell Models you must use either AIR CLEANER RACE KIT Part Number 91421 99Y or AIR CLEANER RACE KIT Part Number 29460 96Y with this carburetor See Service Parts Page Illustrations for kit contents CAUTION Harley Davidson motorcycles equipped with some Screamin Eagle high performance parts may not be used on public roads and in some cases must be restricted to closed course competition This engine related performance part is intended for racing applica tions and is not legal for sale or use in California on pol lution controlled motor vehicles Engine related perfor mance parts are intended for the experienced rider only Removal of Stock Air Cleaner and Carburetor All Models NOTE Refer to the applicable Service Manual for more detailed instructions when removing the components referenced in Steps 1 through 6 Service Manuals are available from your Harley Davidson Dealer WARNING To protect against shock and accidental start up of vehicle disconnect the negative battery cable before proceeding Inadequate safety precautions could res
6. screws are too long and will pre vent O ring sealing interface between adapter and carb CAUTION Check that carb is fully inserted into the manifold If the carb is not fully seated air leaks might result 1 See Service Parts Illustration on Page 7 Insert the large diameter O ring into the adapter and install the adapter onto the front of the carburetor 2 Install the Air Cleaner support bracket to the cylinder heads 3 Attach the backplate assembly to the adapter using 1 4 20x1 4 inch screws or the stock original backplate assembly screws 4 See Service Parts Illustration on Page 7 Refer to Instruction Sheet covering Buell AIR CLEANER RACE KITS and follow instructions given to install air cleaner assembly J01837 Choke Adjustment Stock Choke Cable After mounting choke cable loosen plastic nut to check cable free play If there is no free play make sure cable is fully seated in elbow ae ee ae Imm 0 04 Cable Free Play Figure 10 Proper Choke Cable Free Play Starting Pull choke out fully leave throttle closed and crank engine with starter Push choke knob in as engine warms up and engine runs smoothly RECOMMENDED TUNING PROCEDURES This carburetor is tuned to run well on a majority of Harley Davidson Buell engine configurations however if fine tuning is required for a particular engine configuration follow the procedures in the tuning instructions supplied with with this kit
7. 7 98 Screw w washer needle valve retainer 27769 98 Needle valve ass y w O ring 27759 98 Float assembly Pin float Screw float pin Packing float bowl Float chamber body Hose overflow O ring drain plug Drain plug Screw float bowl 4 Rod accelerator pump Boot accelerator pump rod Plunger accelerator pump Spring accelerator pump 27765 98 27771 98 27764 98 27758 98 27770 98 27763 98 27766 98 Items shown in bold and with asterisk are included in Carburetor Rebuild Kit P N 29565 98 J01837 9 of 9
8. L Models on Page 5 and perform Step 1 2 Screw the cable adjusters together to make them as short as possible 3 Connect the close cable first then install the open cable See Figure 4 for close up of cable installation NOTE Before inserting the carburetor into the stock manifold check the condition of the rubber seal If the seal is damaged it must be replaced to prevent air leakage The fit between the carburetor and the seal ring is tight For ease of installation it is recommended that the mating surfaces carburetor body and seal ring be lubricated prior to assembly to reduce sur face friction Use liquid dish soap or tire mounting lube for this purpose 4 See Figures 3 and 4 Slip the new V O E S fuel petcock vacuum hose on the carburetor fitting below throttle cable bracket 5 Lubricate only the inside surface of the seal ring that will be in contact with the carburetor Insert the carburetor into the manifold 6 Use a pick or small screwdriver to carefully pry the spe cial retaining washer off the V O E S Discard retaining washer 7 See Figure 5 Rotate the V O E S so that the vacuum line points downward Note V O E S and its mounting bracket have indexing bumps and notches that must be aligned 8 Obtain the new retention washer from kit and install to retain V O E S in this position 103916 I l Accelerator Pump Close Cable Adjusting Screw Lever Stop Screw Ac
9. buretor 4 See Figure 3 This is the Modified Hose Configuration Note the following The heat shield from the petcock hose has been removed and petcock hose has been shortened by 2 inches See Figure 3 Obtain heat shield for V O E S provided in kit and install The V O E S hose will route behind horn on the left side to the V O E S vacuum fittting The Short hose old V O E S has been removed and replaced by a longer 5 1 4 inch hose cut from 9 inch hose supplied with new carb Heat Shield from kit is then installed This hose will route to the vacuum fitting on carburetor J01837 103953 End of Hose To Fuel Petcock Trim 1 2 inch to 5 8 inch from End a A TO Carburetor Figure 1 Trim Fuel Hose At Petcock End i03954 To Fuel Petcock Short Hose to V 0 E S Plastic Manifold Heat Shield Installed on Fuel Petcock Hose To Carburetor Vacuum Fitting Figure 2 Original Vacuum Hose Configuration 103955 Fuel Petcock Hose Trimmed 2 inches New 5 1 4 inch Hose routed to Carburetor Vacuum Fitting Heat Shield For V 0 E S From Kit Hose to V O E S Installed behind Horn on Left Side Figure 3 Modified Vacuum Hose Configuration 2of9 Carburetor Installation XL Models NOTE Prior to installing carb perform initial cable routing as described in Step 1 on Page 5 This will allow the cables to be in position during carburetor installation 1 Refer to Cable Routing X
10. celerator Pump Adjusting Screw Start of stroke Jam Nut hidden 10 11 12 13 14 15 i03915 Retention Connect hose shown in Figure 3 to the V O E S Sandwich the V O E S assembly between the horn and the top motor mount as shown Refer to Figure 4 on Page 3 Refer to the applicable Harley Davidson Service Manual and adjust throttle cables following the instructions given Adjust throttle cable so throttle valve slide opens fully Lever stop screw should touch carb body at wide open throttle To adjust lever stop screw loosen jam nut and turn screw in clockwise or out counterclockwise respectively Adjust the opening cable until the slide can be opened fully Snug the adjuster lock nut Install the choke to the horn mounting bracket Perform Backplate Installation procedures on Page 6 Reinstall the fuel tank and connect fuel hose to fuel pet cock using remaining new clamp supplied in kit Connect vacuum hose to fuel petcock Horn Mounting Top Motor Mount O Q Vacuum Fitting Me Old Position Washer Vacuum Fitting V O E S New Position Open Cable Vacuum Fitting V O E S Fuel Petcock Figure 4 Cable Installation J01837 3 of 9 Carburetor Installation Buell Models NOTE Prior to installing carb perform initial cable routing as described under Cable Routing Buell Models Step 1 on Page 5 This will allow the cables to be in position during car buretor
11. espectively NOTE Turn the handlebar to the right and adjust the throttle free play with the closing cable adjuster to approximately 1 8 inch 9 Use cable strap and secure the remote idle adjuster cable to the frame tube 10 See Figure 7 Route drain hose downward from drain fit ting and continue towards rear wheel through the space between the engine rear cylinder and both rear cylinder push rod covers Continue route downward between gearcase cover and engine crankcase 11 Install the choke to choke mounting bracket and perform Backplate Installation procedures on Page 6 J01837 103956 Open Cable Close Cable Throttle Cable Clamps 103957 Figure 7 Routing Drain Hose Buell 4of9 Cable Routing XL Models Cable Routing Buell Models When installing cables to the new carburetor make cer tain that cables are well lubricated and do not bind when handlebars are turned from lock to lock Improperly installed throttle cables can affect vehicle operation which could result in death or serious injury 1 See Figure 8 Route the throttle cables with large radius curves so that they do not interfere with other compo nents s Route Cables Brake Hose Between Cylinder Head and Top Motor Mount Route aie Cables Between 5 Fork Tube and Brake Figure 8 Throttle Cable Routing XL Models J01837 When installing cables to the new carburetor make cer tain that cables are well l
12. ubricated and do not bind when handlebars are turned from lock to lock Improperly installed throttle cables can affect vehicle operation which could result in death or serious injury 1 See Figure 9 Route the throttle cables with large radius curves so that they do not interfere with other compo nents 103958 Throttle Cables 5 of 9 Attaching Adapter To Backplate XL Models CAUTION In the next step do not use the stock screws from back plate assembly The screws are too long and will prevent O ring sealing interface between adapter and carb h See Service Parts Illustration on Page 7 Insert the large diameter O ring into the adapter While sandwiching the gasket between the adapter and backplate assembly attach the adapter to the backplate assembly with the screws from SCREAMIN EAGLE air cleaner kit Apply 1 or 2 drops of Loctite 243 blue on each of the screws CAUTION Before attaching backplate to cylinder heads check that carb is fully inserted into the manifold If the carb is not fully seated air leaks might result N See Service Parts Illustration on Page 7 Refer to Instruction Sheet covering SCREAMIN EAGLE air cleaner kit and follow instructions given to install air cleaner assembly Attaching Adapter To Backplate Buell Models CAUTION In the next step Do NOT use the screws from Race Air Cleaner Kits Part Numbers 91421 99Y and 29460 96Y to install the adapter The
13. ult in death or serious injury Always disconnect the negative battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 1 Disconnect negative battery cable first followed by posi tive cable 2 Remove stock air cleaner assembly including backplate J01837 Gasoline is extremely flammable and highly explosive under certain conditions Do not smoke or allow open flame or sparks anywhere in the area when servicing any part of the fuel system Failure to comply could result in death or serious injury 3 Turn fuel valve to OFF position Disconnect fuel line at carb and drain any remaining gas into proper container 4 On XL Models Follow instructions in applicable Service Manual and remove fuel tank Use red fuel storage container only Storing gas in unap proved container could create a dangerous situation such as leakage leading to explosion or fire hazard which could result in death or serious injury 5 Disconnect choke enrichener cable from mounting bracket on left side of bike D Remove carburetor from manifold N Disconnect throttle Open and Close cables at carbure tor NOTE This carburetor is designed to work with stock throttle cables so complete removal of stock cables is NOT required Oo Disconnect Vacuum Operated Electrical Switch VOES 9 Follow
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