EVO: Carburetor, Intake Manifold & Exhaust


Overview

From 1986-1987, the stock Sportster carburetor was a Keihin 34mm, fixed-venturi “butterfly” model, as used on the Ironhead models from 1979 onward (BT models still used the 38mm version). Contrary to popular folklore, all Keihin non-CV carbs did come with accelerator pumps.

In 1988, the stock Sportster carburetor was upgraded to a Keihin 40mm, slide-type, constant-velocity model. It was quickly discovered that the lack of an accelerator pump was a shortcoming. To help that situation, a special needle, identified as 27094-88 or N65C, was used to help off-idle performance in the 1988 models.

In 1989 and thru 2006, the Keihin CV40 carburetors were produced with an accelerator pump to smooth out initial throttle response.


Keihin non-CV Carburetor (Stock on 1976L-1987)

  • The Keihin non-CV carburetor is a horizontal type with a fuel bowl, single ring-shaped float, an accelerating pump, idle mixture adjusting needle and a throttle stop screw for speed adjustment. 1)
  • The throttle body casting contains an integral venturi and a fuel valve seat that is pressed into the body. The underside of the throttle body contains a boss. The main jet screws into the boss and holds the bleed tube in place.2)
    • Operation: Fuel from the gas tank passes through the fuel valve, onto float chamber. The fuel entering causes the float to rise until it shuts off the fuel valve, stopping the flow at a level predetermined by float level setting. 3)
    • Idle or Slow System: The slow system functions at idle, low and intermediate speeds when throttle valve is closed or only partially open. At idle, fuel enters the main jet and, after being metered there, enters the slow jet where it is metered again. Fuel from the slow jet enters the slow jet bleed tube where it mixes with air through the slow air passage. Fuel mixture is regulated by adjusting the idle (low speed) mixture screw. When the throttle valve is closed, fuel mixture flows into the venturi almost entirely through the idle port. As the throttle valve gradually opens, fuel mix discharge is transferred to the bypass. The slow jet bleed tube is actually a part of the slow jet. 4)
    • The Main System: The main system functions at intermediate and high speeds as the throttle valve opens further. Fuel is metered by the main jet and enters the main jet air passage. The fuel/ air mixture then exits from the main nozzle and into the venturi. 5)
    • The Accelerating Pump System: The accelerating pump system works with sudden throttle openings (rapid acceleration) to quickly inject fuel into the carb to provide extra fuel for the engine demand. Rapid throttle action pushes the pump rod down, flexing the diaphragm, which compresses fuel underneath the diaphragm, forcing it up past the check valve and out the pump nozzle into the venturi. The check valve prevents backflow while the pump nozzle meters the flow. Spring action then returns the diaphragm back to it's original position. As the diaphragm returns, a new supply of fuel flows in and under it so the system will be ready to repeat the cycle with the next rapid throttle action detected. 6)
    • The Choke System: The choke is manually set by pulling out on the choke button. Pulled all the way out is fully closed (for cold engine), partially open (for warm engine) or pushed all the way in, fully open (for warm engine). 7)
  • Integral Float Chamber
  • Manual Choke
  • 3 different models
  • 1976L-1978 have 38mm Venturi
  • 1979-1987 have 34mm Venturi
  • Model Year Changes

1986-1987 Features 8)

  • 34mm Venturi
  • Horizontal, gravity fed with a float operated inlet valve
  • Throttle stop screw
  • Fast idle cam
  • Choke system with fast idle adjustment
  • Accelerator pump
  • Designed to control exhaust emissions
  • Fixed jets
  • Factory preset idle mixture
  • For those sold for use in California (as part of the evaporative emissions kit) the fuel overflow fitting was capped and the overflow line was removed. 9)

Idle Mixture Screw

An aftermarket kit (like E-Z-just for L76-87 models 10) ) can be purchased with an extended screw head for hand tuning.
It comes with the “packing” in case yours has been damaged or is not functioning properly.
But, check your local regulations before changing this out to an aftermarket part.
You can also find, buy or barter for used parts.
(“Please note: it is a violation of federal law to tamper with or disable any emission or noise control device. That is your PSA for the day”). 11)

Stock idle mixture screw 12) Stock mixture screw (top) compared to the
E-Z-Just mixture screw (bottom) 13)
The aftermarket thumb screw head doesn't a slot for a screwdriver (which also serves as a visual for position).
A small hole drilled off center will give a visual position of the screw for adjustment later. 14)


Factory Keihin non-CV 34mm Carb by Sportster Model/Year

Sportster ModelYearKeihin Non-CV 34mm
Carb Serial #
Main / Slow
Jet Size 15)
Main / Slow
Jet Part #s
XLH 883, '87 XLH 883/Hug (50 States)1986-198727501-86A (B83H)15516) / 5217)(27089-78) - (27329-83)
XLH 1100 (50 States)198627502-86B (B83H)15518) / 5219)(27089-78) - (27329-83)
XLH 1100 (50 States)198727502-86B (B83H)15020) / 5221)(27087-80) - (27329-83)
Main & Slow jet sizes are the same (86-87) 883 & (86) 1100. BUT - Due to internal differences, the carbs are not interchangeable 22)
  • Note: Main and slow jet sizes are the same for the 86-87 883 and the 86 1100 carbs. But, due to internal differences, the carbs are not interchangeable.23)
Carb Idle Speed 900 RPM 24)
Torque Specs 25)
1986-1987 Carb to Intake Manifold Bolts 15-17 in/lbs (20-23 NM)
* Intake Manifold Flange to Cylinder Head Bolts/Nuts 72-120 in/lbs (8-14 Nm)
* Air Cleaner Backplate to Engine Bolts 120-144 in/lbs (14-16 Nm)
* Air Cleaner to Carburetor Bolts 36-60 in/lbs (4-7 Nm)
* Air Cleaner Cover Screws 36-60 in/lbs (4-7 Nm)

Interesting discussion here: http://xlforum.net/forums/showthread.php?t=1847273


Pics of Keihin non-CV Carbs

(Factory Installed Carbs)

1977 Keihin 38mm non-CV pic 126)1977 Keihin 38mm non-CV pic 227)


Keihin BD

  • Used in the Screaming Eagle Package line from HD as an Evolution XLH HI-FLO Carburetor & Air Cleaner. The carb was a (27001-88)
  • Adjustable Accelerator Pump stroke
  • Incorporated a special intake manifold to carb spacer that had to be drilled and tapped (1/4 x 28) in the side for included Voes connection adapter
  • Required a 1987 replacement style intake manifold for 1988 and up models
  • Required possible grinding of the right rear corner of the front cylinder head, due to interference with the carburetor throttle pulley and cable guides, for proper clearance 28)
PART NUMBERS & JET SIZES (IN MM) FOR KEIHIN BD CARBURETORS
Slow Jet Size Int. Air/Fuel Jet Size Main Jet Size
27383-88 42 27113-87 Blank* 27106-85 1.30
27302-84 50 27109-87 55 27107-85 1.35
27329-83 52 27172-89 60* 27149-85 1.40
27284-85 55 27110-87 80 27151-85 1.45
27310-85 58 27111-87 1.00 27150-85 1.50
27318-85 60 27112-87 1.20 27108-87 1.60*
27283-85 62 27173-89 1.70 27119-88 1.65
27896-79 65 27134-89 1.70
27894-78 68*
27895-87 70
27897-78 72
* in carburetor

29)


Keihin CV 40mm Carb (1988-2006)

  • Constant velocity, gravity fed - has a float-operated inlet valve and a vacuum-operated variable venturi (movable slide).
Torque Specs
1988-2001 Intake Manifold Flange to Cylinder Head Bolts/Nuts 72-120 in/lbs (8-14 Nm)
2002-Later Intake Manifold Flange to Cylinder Head Bolts/Nuts 96-144 in/lbs (10.9-16.3 Nm)
All Carb Clamp Screw 10-15 in/lbs (1.1-1.7 Nm)
Operation:
  • The carburetor atomizes gas in proper proportions to the air pulled in through the air intake. At idle, a small amount of gas is siphoned through the pilot jet by the incoming air. The more the throttle is opened, the air begins siphoning through the main and needle jets. The tapered needle increases the flow of the needle jet as it is lifted since it's taper gets smaller as it sets inside the needle jet thus allowing for more flow when lifted up and out. Vacuum from carbs intake,the engine side of the throttle plate, is used to lift the slide barrel/ needle jet. At full throttle, the carburetor venturi is fully opened and the needle is lifted far enough to allow the main jet to flow at full jet capacity. The choke circuit is actually the starting enrichment valve system. The choke knob opens an enrichment valve. With the choke knob in the open position, the slow jet sends a stream of gas into the carburetor's venture thus enriching the gas/air mixture when the engine is cold. The accelerator pump circuit injects a fine spray of gas into the carburetor intake during sudden acceleration to reduce engine hesitation.

Serial Number:

  • Labeled on the adjacent side to the accelerator pump linkage

Example 27231-98 translates to

Keihin CV Serial NumberYear of IntroductionNotes
27231 1998 Can be used on same year and / or future multiple models


Factory Keihin CV40 Carburetors by Sportster Model/Year

Emissions Observations

by Almond farmer: 30)

  • There were no HC emissions changes from 1981-2003 @ 2.5 g/km .
    • 78-79 is 14 g/km
    • 80-81 is 5 g/km
  • Any carburetor can meet those standards
  • In 2004 CARB went to 1.4 g/km and EPA (49 states)in 2006, last year for XL carburetor.
  • CA is the only state in the country with its own emissions standards which are currently the same as the EPA standards.
  • In 2008 CARB mandated only .8 k/km HC and EPA with the same requirement, followed two years later in 2010.

The above #s are combined HC + NOX

  • Noticed the Keihin 40mms CV used 160 main jet for the 883 up to 2003, then 2004-2006 went to 175 (1.75mm) for 49 state bikes, not CA bikes.
  • This change makes the air/fuel mixture run richer, therefore, a richer mixture results in lower combustion temperature with resulting lower HC +NOX to meet more stringent emission standards.
  • Notice the 49 state 1200 used 170 jet up to 2004, 180 main jet (MJ) in 2004, & 185 MJ in 2005-2006.
  • CA 883 went from 170 MJ to 2003 then changed to 180 MJ in 2005-2006.
  • Again making the air/fuel ratio richer.
  • CA 1200 cc went from 160 MJ in 1989 to 185 MJ in 2006. So, the 2006, 1200 evo with Keihin 40mms CV with vertical needle used the same main jet (1.85mm)for all 50 states, since CARB & EPA had the same emission requirements on the MoCo in that time.
  • Note that jets are selected for operation at below 4000 ft elevation.
  • If installing CV to 1000cc IH would first select 170 main jet below 4000 ft elevation. This Keihin CV should return lower emissions than any of the Keihin Butterfly carburetors and even satisfied the tier 1 CARB emissions requirements.
  • Unfortunately, CV could satisfy tier 2 emissions at only .8 g/km.


U S A (Domestic) Sportster Models

 Annotated by IXL2Relax at the XLForum Photo by IXL2Relax at the XLForum Example Parts Shown Here »>


All CV40 carbs use the following parts & P/N:

27100-88 - Needle Jet (.114“ ID)31)
27101-88 - Emulsion Tube (Needle Jet Holder)
27585-88 - Vacuum Slide (Vacuum Piston)


Sportster ModelYear Keihin CV 40mm
Carb Serial #
Main / Slow
Jet Size 32)
Main / Slow Jet
(Part #s)
Keihin Needle
for Vac Slide33)
XL883 (Dom)198827501-88
No Accel Pump
170 / 35(27115-88) - (27117-88)N65A (27091-88)
1989-199027501-89175 / 45(27090-89) - (27170-89)N72A (27166-89)
199127501-89A175 / 45(27090-89) - (27170-89)N72A (27166-89)
199227489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
1993-199427489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
199527489-92A160 / 40(27152-89) - (27281-92)N86Q (27183-92)
199627490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
Listed for (Cal) only
199727490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
199827490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
1999-200127490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
2002-200327490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
2004-200627490-04175 / 42(27090-89) - (27171-89)N9EY (28027-04)
XL883C (Dom)199827490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
1999-200127490-96160 / 42(27152-89) - (27271-89)
2002-200327490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
2004-200627490-04175 / 42(27090-89) - (27171-89)N9EY (28027-04)
XL883 Hug (Dom)198827501-88
No Accel Pump
170 / 35(27115-88) - (27117-88)N65A (27091-88)
1989-199027501-89175 / 45(27090-89) - (27170-89)N72A (27166-89)
199127501-89A175 / 45(27090-89) - (27170-89)N72A (27166-89)
199227489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
1993-199427489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
199527489-92A160 / 40(27152-89) - (27281-92)N86Q (27183-92)
199627490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
Listed for (Cal) only
199727490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
199827490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
1999-200127490-96160 / 42(27152-89) - (27271-89)NOKK (27241-95)
2002-200327490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
XL883 Deluxe (Dom)198827501-88
No Accel Pump
170 / 35(27115-88) - (27117-88)N65A (27091-88)
1989-199027501-89175 / 45(27090-89) - (27170-89)N72A (27166-89)
199127501-89A175 / 45(27090-89) - (27170-89)N72A (27166-89)
199227489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
1993-199427489-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
199527489-92A160 / 40(27152-89) - (27281-92)N86Q (27183-92)
XL883L (Dom)2005-200627490-04175 / 42(27090-89) - (27171-89)N9EY (28027-04)
XL883R (Dom)2002-200327490-96A160 / 42(27152-89) - (27271-89)NOKK (27241-95)
2005-200627490-04175 / 42(27090-89) - (27171-89)N9EY (28027-04)
XL1200 (Dom)198827502-88200 / 35(27105-88) - (27117-88)N65C (27094-88)
198927502-89175 / 45(27090-89) - (27170-89)N72E (27168-89)
199027501-89175 / 45(27090-89) - (27170-89)N72A (27166-89)
199127501-89A175 / 45(27090-89) - (27170-89)N72A (27166-89)
1992-199427487-92170 / 40(27115-88) - (27281-92)N86P (27280-92)
199527487-92A160 / 40(27152-89) - (27281-92)N86P (27280-92)
199627491-96160 / 42(27152-89) - (27171-89)N86P (27280-92)
199727480-97170 / 42(27115-88) - (27171-89)NOKK (27241-95)
199827480-97A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
1999-200127480-97170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2002-200327480-97A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
XL1200C (Dom)199627491-96160 / 42(27152-89) - (27171-89)N86P (27280-92)
199727480-97170 / 42(27115-88) - (27171-89)NOKK (27241-95)
199827480-97A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
1999-200127480-97170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2002-200327480-97A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
200427731-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
2005-200627731-04185 / 42(27185-90) - (27171-89)N4NN (28026-04)
XL1200R (Dom)200427731-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
2005-200627731-04185 / 42(27185-90) - (27171-89)N4NN(28026-04)
XL1200S (Dom)199627491-96160 / 42(27152-89) - (27171-89)N86P (27280-92)
199727480-97170 / 42(27115-88) - (27171-89)NOKK (27241-95)
NOTE: 1998-2003 1200S carbs have no float bowl overflow tube protection
They also have no drain plug & hose to empty float chamber for off riding season or extended storage
199827731-98A19534) / 42(27275-96Y) - (27171-89)NOKK (27241-95)
1999-200127731-98195 / 42(27275-96Y) - (27171-89)(27656-98)
2002-200327731-98A195 / 42(27275-96Y) - (27171-89)(27656-98)

U S A (California) Sportster Models

 Annotated by IXL2Relax at the XLForum Photo by IXL2Relax at the XLForum Example Parts Shown Here »>


All CV40 carbs use the following parts & P/N:

27100-88 - Needle Jet (.114” ID)35)
27101-88 - Emulsion Tube (Needle Jet Holder)
27585-88 - Vacuum Slide (Vacuum Piston)


Sportster ModelYear Keihin CV 40mm
Carb Serial #
Main / Slow
Jet Size 36)
Main / Slow Jet
(Part #s)
Keihin Needle
for Vac Slide37)
XL883 (Cal)198827504-88
No Accel Pump
165 / 35(27116-88) - (27117-88)N65B (27092-88)
198927504-88A? / 42
155 / 42 38)
(27154-88)39) - (27171-89)
(27154-89)40) - (27171-89)
N72B (27167-89)
199027503-88A? / 42
160 / 42 41)
(27152-88)42) - (27171-89)
(27152-89)43) - (27171-89)
N72F (27169-89)
199127503-88B160 / 42(27152-89) - (27171-89)N72F (27169-89)
1992- Early 199327488-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
Late 1993-199427488-92A170 / 40(27115-88) - (27281-92)N86K (27278-93)
199527488-92B170 / 40(27115-88) - (27281-92)N86K (27278-93)
1996-199727495-96170 / 42(27115-88) - (27171-89)NOKK (27241-95)
199827495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
1999-200127495-96170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2002-200327495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
200427495-04185 / 42(27185-90) - (27171-89)N4NN (28026-04)
2005-200627495-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
XL883C (Cal)199827495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
1999-200127495-96170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2002-200327495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
200427495-04185 / 42(27185-90) - (27171-89)N4NN (28026-04)
2005-200627495-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
XL883 Hug (Cal)198827504-88
No Accel Pump
165 / 35(27116-88) - (27117-88)N65B (27092-88)
198927504-88A? / 42
155 / 42 44)
(27154-88)45) - (27171-89)
(27154-89)46) - (27171-89)
N72B (27167-89)
199027503-88A? / 42
160 / 42 47)
(27152-88)48) - (27171-89)
(27152-89) - (27171-89)
N72F (27169-89)
199127503-88B160 / 42(27152-89) - (27171-89)N72F (27169-89)
1992- Early 199327488-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
Late 1993-199427488-92A170 / 40(27115-88) - (27281-92)N86K (27278-93)
199527488-92B170 / 40(27115-88) - (27281-92)N86K (27278-93)
1996-199727495-96170 / 42(27115-88) - (27171-89)NOKK (27241-95)
199827495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
1999-200127495-96170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2002-200327495-96A170 / 42(27115-88) - (27171-89)NOKK(27241-95)
XL883 Deluxe (Cal)198827504-88
No Accel Pump
165 / 35(27116-88) - (27117-88)N65B (27092-88)
198927504-88A165 / 42(27116-88) - (27171-89)N72B (27167-89)
199027503-88A165 / 42(27116-88) - (27171-89)N72F (27169-89)
199127503-88B160 / 42(27152-89) - (27171-89)N72F (27169-89)
1992- Early 199327488-92160 / 40(27152-89) - (27281-92)N86Q (27183-92)
Late 1993-199427488-92A170 / 40(27115-88) - (27281-92)N86K (27278-93)
199527488-92B170 / 40(27115-88) - (27281-92)N86K (27278-93)
XL883L (Cal)2005-200627495-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
XL883R (Cal)2002-200327495-96A170 / 42(27115-88) - (27171-89)NOKK (27241-95)
2005-200627495-04180 / 42(27114-88) - (27171-89)N4NN (28026-04)
XL1200 (Cal)198827503-88
No Accel Pump
180 / 35( 27114-88) - (27117-88)N65D (27099-88)
1989-199027503-88A? / 42
16049) / 42
( 27152-88 ) 50)
(27152-89) - (27171-89)
N72F (27169-89)
199127503-88B160 / 42( 27152-89) - (27171-89)N72F (27169-89)
1992-Early 199327486-9217051) / 40(27115-88)- (27281-92)N86P (27280-92)
Late 1993-199427486-92A185 / 40(27185-90) - (27281-92)N86J (27279-93)
199527486-92B 185 / 40(27185-90) - (27281-92)N86J (27279-93)
1996-199727498-96185 / 42(27185-90) - (27171-89)N86J (27279-93)
199827498-96A 185 / 42(27185-90) - (27171-89)N86J (27279-93)
1999-200127498-96185 / 42(27185-90) - (27171-89)N86J (27279-93)
2002-200327498-96A185 / 42(27185-90) - (27171-89)N86J (27279-93)
XL1200C (Cal)1996-199727498-96 185 / 42(27185-90) - (27171-89)N86J (27279-93)
199827498-96A185 / 42(27185-90) - (27171-89)N86J (27279-93)
1999-200127498-96185 / 42(27185-90) - (27171-89)N86J (27279-93)
2002-200327498-96A185 / 42(27185-90) - (27171-89)N86J (27279-93)
2004-200627732-04185 / 42(27185-90) - (27171-89)N4NN (28026-04)
XL1200R (Cal)2004-200627732-04185 / 42(27185-90) - (27171-89)N4NN (28026-04)
XL1200S (Cal)199627498-96185 / 42(27185-90) - (27171-89)N86J (27279-93)
199727498-96195 / 42(27275-96Y) - (27171-89)N86J (27279-93)
NOTE: 1998-2003 1200S carbs have no float bowl overflow tube protection
They also have no drain plug & hose to empty float chamber for off riding season or extended storage
199827732-98A195 / 42(27275-96Y) - (27171-89)N86J (27279-93)
1999-200127732-98195 / 42(27275-96Y) - (27171-89)(27254-96)
2002-200327732-98A195 / 42(27275-96Y) - (27171-89)(27254-96)

H D I Sportster Models

 Annotated by IXL2Relax at the XLForum Photo by IXL2Relax at the XLForum Example Parts Shown Here »>


All CV40 carbs use the following parts & P/N:

27100-88 - Needle Jet (.114“ ID)52)
27101-88 - Emulsion Tube (Needle Jet Holder)
27585-88 - Vacuum Slide (Vacuum Piston)


Sportster ModelYear Keihin CV 40mm
Carb Serial #
Main / Slow
Jet Size 53)
Main / Slow Jet
(Part #s)
Keihin Needle
for Vac Slide54)
XL883 Swiss
All Models
1989-199027492-89
No Accel Pump
? / 35(27104-89) - (27117-88)? (27164-89?)
XL883
HDI / Swiss
1989-199027501-88
No Accel Pump
? / 35(27104-89) - (27117-88)? (27164-89)
XL883 Swiss199127503-88B160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss199227503-92160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss1993-199427503-92A160 / 40(27152-89) - (27281-92)N65J(27187-93)
HDI1995-199727031-95190 / 42(27243-95) - (27171-89)N65J (27187-93)55)
HDI199827031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI1999-200027031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI/Eng/Japan 200127465-01165 / 42(27116-88) - (27171-89)NOKL (28013-01)
HDI
Eng/Japan
2002-200327465-01A165 / 42(27116-88) - (27171-89)NOKL (28013-01)
Aust200127031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
Aust2002-200327031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI2004-200627465-04165 / 42(27116-88) - (27171-89)N9EY (28027-04)
XL883C HDI1999-200027031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI/Eng/Japan 200127465-01165 / 42(27116-88) - (27171-89)NOKL (28013-01)
HDI/Eng/Japan 2002-200327465-01A165 / 42(27116-88) - (27171-89)NOKL (28013-01)
Aust200127031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
Aust2002-200327031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI2004-200627465-04165 / 42(27116-88) - (27171-89)N9EY(28027-04)
XL883 Hug Swiss199127503-88B160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss199227503-92160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss1993-199427503-92A160 / 40(27152-89) - (27281-92)N65J(27187-93)
HDI1995-199727031-95190 / 42(27243-95) - (27171-89)N65J (27187-93)56)
HDI199827031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI1999-200027031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI/Eng/Japan 200127465-01165 / 42(27116-88) - (27171-89)NOKL (28013-01)
HDI/Eng/Japan 2002-200327465-01A165 / 42(27116-88) - (27171-89)NOKL (28013-01)
Aust200127031-95190 / 42(27243-95) - (27171-89)NOKD (27242-95)
Aust2002-200327031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
XL883 Deluxe Swiss199127503-88B160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss199227503-92160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss1993-199427503-92A160 / 40(27152-89) - (27281-92)N65J(27187-93)
HDI199527031-95190 / 42(27243-95) - (27171-89)N65J (27187-93)
XL883L
HDI
2005-200627465-04165 / 42(27116-88) - (27171-89)N9EY(28027-04)
XL883R
HDI/Eng/Japan
2002-200327465-01A165 / 42(27116-88) - (27171-89)NOKL (28013-01)
Aust 2002-200327031-95A190 / 42(27243-95) - (27171-89)NOKD (27242-95)
HDI 2005-200627465-04165 / 42(27116-88) - (27171-89)N9EY (28027-04)
XL1200
HDI / Swiss
1988-1990
No Accel Pump
27502-88? / ?(?) - (?)? - (?)
Swiss1989-1990
No Accel Pump
27491-89? / 35(27104-89) - (27117-88)? (27165-89)
Swiss199127503-88B160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss199227503-92160 / 42(27152-89) - (27171-89)N72F(27169-89)
HDI / Swiss1993-199427503-92A160 / 40(27152-89) - (27281-92)N65J(27187-93)
HDI199527076-95190 / 42(27243-95) - (27171-89)N65J(27187-93)
Swiss 57)199527503-92B160 / 40(27152-89) - (27281-92)N65J(27187-93)
HDI199827076-95A190 / 42(27243-95) - (27171-89)NOKK (27241-95)
HDI1999-200027076-95190 / 42(27243-95) - (27171-89)NOKK (27241-95)
HDI/Aust/Eng/Japan200127076-95190 / 42(27243-95) - (27171-89)NOKK (27241-95)
HDI/Aust/Eng/Japan2002-200327076-95A190 / 42(27243-95) - (27171-89)NOKK (27241-95)
XL1200C
HDI
1996-199727076-95190 / 42(27243-95) - (27171-89)N65J(27187-93)58)
HDI199827076-95A190 / 42(27243-95) - (27171-89)NOKK (27241-95)
HDI1999-200027076-95190 / 42(27243-95) - (27171-89)NOKK(27241-95)
HDI/Aust/Eng/Japan200127076-95190 / 42(27243-95) - (27171-89)NOKK(27241-95)
HDI/Aust/Eng/Japan2002-200327076-95A190 / 42(27243-95) - (27171-89)NOKK(27241-95)
HDI 2004-200627749-04160 / 42(27152-89) - (27171-89)
HDI, Japan
N9EY (28027-04)
XL1200R
HDI
2004-200627749-04160 / 42(27152-89) - (27171-89)
HDI, Japan
N9EY (28027-04)
XL1200S
HDI
1996-199727076-95190 / 42(27243-95) - (27171-89)N65J(27187-93)59)
HDI199827734-98190 60) / 42(27243-95)61) - (27171-89)N86K (27278-93)
Swiss199827733-98195 62) / 42(27275-96Y)63) - (27171-89)N86K (27278-93)
HDI1999-200027734-98200 / 42(27105-88) - (27171-89)N86K (27278-93)
HDI/Aust/Eng/Japan200127749-01185 / 42(27185-90) - (27171-89)(27647-01)
HDI/Aust/Eng/Japan2002-200327749-01A185 / 42(27185-90) - (27171-89)(27647-01)



Pics of Keihin CV40 Carbs

(Factory Installed) — Click on a picture to enlarge:

Keihin CV40 #27731-04

Used on 2004-2006 (Domestic models) 1200C, 1200R64)

Keihin CV40 #27498-96A

Used on 1998, 2002-2003 (California models) 1200, 1200C 65)


Discrepancies in the FSM(s) / Parts Catalog(s)

Upon perusing 1986-2006 Parts Catalogs for carburetor information, it's clear that the MoCo was trying to save space in these books at the expense of legibility. Below is a chart showing the initial intentions on the top and the MoCo's mis-interpretations on the bottom. They give no notations (from year to year book) on any changes to the nomenclature. I.E. one way to display a year/ model number is displayed differently in other year books. This chart is not complete nor factual in numbering but as an example only. For instance:

Parts BookDescriptionFor Model(s)Part fits model(s)Notes
86-9000000-8688 - * XL1200(88-90) XL1200Easy to understand, * means
to the last date the book covers
86-9000000-86 (86-87 883)90-XL1200(86-87) XL883 & (90) XL1200Little harder
(more to think about)
86-9000000-8686-* all models(86-90) XL883 all & (88-90) XL1200Easy to understand, blankets all models 1200
first made in 1988 but it leads you to believe
they were made from '86
86-9000000-86
00000-86 (Cal)
89-* XL1200
88-* XL1200
(89-90) XL1200 - (49 state)except California
(88-90) XL1200 - California only
No suffix after desc. means domestic models
(Cal) after suffix is California models only
91-9200000-86
(91-Cal)
91-* XL1200(91-92) Xl1200 (domestic)
(91) Xl1200 (California)
Both Cal and Dom models
93-9400000-87 (93-Cal)
00000-86
93-* XL883
93-* XL883
(93-94) Xl883 (California) only
(93-94) XL883 all models
Reads it but doesn't mean for Domestic
Domestic (49 state models)

Found and documented discrepancies are in the chart below. I'm sure I didn't list them all 66)

Engine XL883XL1200
2004 FSM (erroneous info)67)49 StateCaliforniaHDI, Swiss49 StateCaliforniaHDI, Swiss
Main Jet
Corrected Size 68)
160
175
170
180
190
170
175/190
180
185-195
185
200
160
2002, 2003 Parts Catalogs show a Cali 883R carb but no jet sizes or other carb parts.
Listed same year 883 (Cali) data.69)
1999, 2000 Parts Catalogs do not list part number for a (Cali) main jet size for the 1200S.
Listed same year (Dom) jet sizes.70)
1999, 2000 Parts Catalog does not list part number for a (Cali) main jet size for the 883C.
Listed same year (Cali) 883 jet sizes.71)
1998 Parts Catalog shows a 170 and a 195 main jet for Dom 1200S.
Verified with 1998 HD Sportster FSM to be a 195.72)
1998 Parts Catalog pg 135 lists differences between the mid-year intro 883C and 883Std.
Reads other than what's listed, use 883Std parts. No carb parts listed so Std 883 specs used.73)
1998 Parts Catalog pg 23 shows Swiss 1200S with (27114-88) 180 main jet but no main jet for HDI. Also there is no jet needle specified for Swiss 1200S
Listed jet sizes from 1998 HD FSM pg 4-1 showing Swiss (195), HDI (190). Also listed Swiss 1200S jet needle as same year HDI 1200S 74)
1998 Parts Catalog shows 1200S (Dom) main jet as a 170 (27115-88).
Corrected to a 195 main jet with the 1998 HD XLH FSM pg 4-1.75)
1993-1994 Parts Catalog makes it impossible to verify a main jet without the FSM to translate;
27115-88 Main Jet (Late 1992 and Later 883 Cal.) 93-94 All ModelsTranslates to Cal 883 (170) & Dom 1200 (170)76)
27152-89 Main Jet (1200 HDI and Swiss) 93-94 All ModelsTranslates to Dom, HDI/Swiss 883 (160) & HDI/Swiss 1200 (160)77)
27185-90 Main Jet (Cal only) L93-94 1200Normal listing which is a Late 93-94 Cal 1200 (185)78)
1991-1992 Parts Catalog is confusing to show (Cal)1200 main jet as: (170) 27115-88 - main Jet (Dom) - 92 and on * -all models.79)
1991-1992 Parts Catalog is confusing to show (Cal)883 main jet as: (160) 27152-89 - main Jet (1991 Cal & Swiss; 1992 & later All 883, 1200 HDI & Swiss - 1991-1992 models. Doesn't seem to group (Cal)883 into the 92 models. Verified with 1991-1992 FSM pg 4-180)
1990 Parts Catalog does not list a main jet for an XL1200 (Domestic) model.
Verified with the 1986-1990 FSM pg 4-1.81)
1986-1990 Parts Catalog has an errant main jet #27154-88 for (Cal) 883s. Confirmed as a 155 with the 1986-1990 Sportster FSM pg 4-1, cross referenced to serial #27154-89 82)83)
1986-1990 Parts Catalog is very confusing on export model carb info. I.E.,
The carb numbers are (all with no accel pump):
27491-89 / (Swiss only) / 89-90 XLH1200
27492-89 / Swiss only / 89-90 XLH883 All Models
27501-88 / HDI only-1989 & later / 88-90 XL883 All Models
27502-88 / HDI only-1989 & later / 88-90 XLH1200
These are the only main jets designated for export motors:
27102-89 / Main Jet (Swiss only) / 89- XLH 883 All Models
27104-89 / Main jet (Swiss only) / 89-90 All Models
These are the only slow jets designated for export motors:
27117-88 / Slow jet (Swiss only-1989) / 88 & 89 All Models
These are the only needle jets designated for export motors:
27164-89 (Swiss only) / 89- XLH 883 All models
27165-89 (Swiss only) / 89- XL1200
Everything else is either designated Domestic or California engines. 84)

1) , 2) , 3) , 4) , 5) , 6) , 7)
1970-1978 HD XL/XLH/XLCH/XLT 1000 FSM
8)
1986-1990 HD Sportster FSM
9)
HD Service Bulletin #M-905 dated August 26, 1985
11)
XLForum member - chrishajer
15) , 32) , 33) , 36) , 37) , 40) , 43) , 46) , 49) , 53) , 54) , 61) , 63) , 82)
Cross-reference numbers by Folkie from the XLFORUM http://xlforum.net/forums/showthread.php?t=2006132&page=7
16) , 17) , 18) , 19) , 20) , 21) , 22)
1986-1990 HD XLH FSM pg 4-1
23)
1986-1990 HD XLH FSM
24)
Clymer Sportster Repair Manual 1959-1985
25)
1970-2010 Haynes Sportster Service and Repair Manual pgs 3.1-3.2
34) , 60) , 62)
1998 HD XLH FSM pg 4-1
38) , 41) , 44) , 47)
1886-1990 HD Sportster FSM pg 4-1
39) , 42) , 45) , 48)
1986-1990 HD Sportster Parts Catalog pg 23
50)
'86-'90 parts catalog lists 27152-88. Corrected to 27152-89 by the '86-'90 FSM and ((Cross-reference numbers by Folkie from the XLFORUM http://xlforum.net/forums/showthread.php?t=2006132&page=7
51)
1991-1992 HD Sportster FSM pg 4-1
55) , 56)
Not listed in 1997 Parts Catalog
57)
all models: 95-96 Parts Catalog doesn't say which models were shipped Swiss
58) , 59)
Not listed in 2007 Parts Catalog
64)
Photo by rocketmangb of the XLFORUM
65)
photos courtesy of blackbikedave of the XLFORUM http://xlforum.net/forums/showthread.php?threadid=2013441
66)
Hippysmack
68)
Verified with the 2004 HD Sportster Parts Catalog pgs 21,23
69) , 70) , 71) , 72) , 73) , 74) , 75) , 76) , 77) , 78) , 79) , 80) , 81) , 83) , 84)
hippysmack
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