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techtalk:ih:carb02 [2017/11/26 04:18]
hippysmack [Tillotson HD Carburetor (1966-1971)] 		techtalk:ih:carb02 [2019/09/12 21:47]
hippysmack removed
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 * . . . [[techtalk:​ih:​carb02a|Finding and fixing the cause of the degradation that leads to intake manifold leaks]] * . . . [[techtalk:​ih:​carb02a|Finding and fixing the cause of the degradation that leads to intake manifold leaks]]
  
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-__Underlined Text__ 
 ====== Tillotson HD Carburetor (1966-1971) ====== ====== Tillotson HD Carburetor (1966-1971) ======
 +===== Testing and Repair Checklist =====
  
-  * On January 15, 1968, the MoCo issued a service checklist to aid in testing and repairing (instead of returning for warranty) Tillotson carburetors due to some dealers having difficulty diagnosing problems on 1966 → Sportsters & 1967 → Electra Glides. +  ​* **On January 15, 1968, the MoCo issued a service checklist to aid in testing and repairing (instead of returning for warranty) Tillotson carburetors due to some dealers having difficulty diagnosing problems on 1966 → Sportsters & 1967 → Electra Glides.** ((HD Service Bulletin #564 dated January 15, 1968)) 
-  * Before disassembling the carb to correct any (non)performance,​ it should first be established that external adjustments have been made and are correct. In many cases, the intermediate and idle speed needles are incorrectly adjusted cause poor performance. ​+  * Before disassembling the carb to correct any (non)performance,​ it should first be established that external adjustments have been made and are correct. In many cases, the intermediate and idle speed needles are incorrectly adjusted cause poor performance. ​((HD Service Bulletin #564 dated January 15, 1968))
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   * Correct adjustment can be determined in the shop and verified by a road test:   * Correct adjustment can be determined in the shop and verified by a road test:
-  * **Adjustments** (a tachometer is recommended):​+  * **Adjustments** (a tachometer is recommended): ​((HD Service Bulletin #564 dated January 15, 1968))
     - Seat idle and intermediate needles, gently, and open both 7/8 turn.     - Seat idle and intermediate needles, gently, and open both 7/8 turn.
     - Start the engine and warm up for at least 3 minutes at fast idle.     - Start the engine and warm up for at least 3 minutes at fast idle.
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   * All these tests should be performed (in sequence) before further disassembly or repairs are made.   * All these tests should be performed (in sequence) before further disassembly or repairs are made.
-  * **Testing** (prior to removal from engine):+  * **Testing** (prior to removal from engine): ​((HD Service Bulletin #564 dated January 15, 1968))
     - The accelerator pump should be inspected for proper operation. Remove the air cleaner and prime the carburetor by inserting a toothpick through the small hole in the bottom of the plastic pump cover and gently work the diaphragm several times. Operate the throttle lever (both rapidly and then slowly several times with the fuel valve turned on. The pump should deliver a strong & constant jet of fuel with each stroke. Failure to do so indicates defective diaphragm valves or pump plunger.     - The accelerator pump should be inspected for proper operation. Remove the air cleaner and prime the carburetor by inserting a toothpick through the small hole in the bottom of the plastic pump cover and gently work the diaphragm several times. Operate the throttle lever (both rapidly and then slowly several times with the fuel valve turned on. The pump should deliver a strong & constant jet of fuel with each stroke. Failure to do so indicates defective diaphragm valves or pump plunger.
     - Clean the high, intermediate & low speed channels to (most likely) dislodge any loose dirt in the passages. Remove the high speed screw plug located on the rear side of carburetor opposite intermediate adjustment needle. Lightly seat the intermediate needle and apply air pressure (90 psi max.) to the screw plug hole. Next, open the intermediate and idle needles three or four turns and again apply air pressure (90 psi max.). Reset both adjustment screws (see adjusting measures above). Ride the bike to evaluate the carburetor'​s performance.     - Clean the high, intermediate & low speed channels to (most likely) dislodge any loose dirt in the passages. Remove the high speed screw plug located on the rear side of carburetor opposite intermediate adjustment needle. Lightly seat the intermediate needle and apply air pressure (90 psi max.) to the screw plug hole. Next, open the intermediate and idle needles three or four turns and again apply air pressure (90 psi max.). Reset both adjustment screws (see adjusting measures above). Ride the bike to evaluate the carburetor'​s performance.
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     - Inspect the idle needle and seat in the carburetor bore for any distortion or a cracked casting.     - Inspect the idle needle and seat in the carburetor bore for any distortion or a cracked casting.
     - Inspect the choke relief disc (upper half of the choke) for distortion or stress cracks at the area rotating on the choke shaft.     - Inspect the choke relief disc (upper half of the choke) for distortion or stress cracks at the area rotating on the choke shaft.
-    * Disassembly,​ inspection and replacement of parts (__replace damaged parts only after completing all of the above tests__).+    ​* **Disassembly,​ inspection and replacement of parts** (__replace damaged parts only after completing all of the above tests__). ​((HD Service Bulletin #564 dated January 15, 1968))
     - Remove the plastic ​ diaphragm ​ cover and inspect the accelerator pump leather for fold-over or the coil spring out of the correct position. Check the accelerator pump outlet ball check valve to see that the ball is  free (Late 1968). Inspect the gasket and diaphragm for distortion or misplacement on the carb body. The diaphragm must not be stretched or have a rippled appearance particularly within the valley portion which should be uni­form in shape (gasket should be assembled next to the body). \\ Lightly, attempt to rotate the metal diaphragm washer (riveted to the upper side of the diaphragm). If the diaphragm plate rotates freely with no drag, replace the diaphragm assembly. The diaphragm plate should not be loose. Prior to removal of the inlet lever, the initial needle seat leakage test should be performed 10-12 times with the bulb tester. Close the bulb valve. Apply pressure to the inlet to seal the vent fitting. Open the bulb valve and again apply pressure. This repetition checks the sealing of the needle in the seat insuring that it is not sticking open at the lever pin or at the groove in the needle.     - Remove the plastic ​ diaphragm ​ cover and inspect the accelerator pump leather for fold-over or the coil spring out of the correct position. Check the accelerator pump outlet ball check valve to see that the ball is  free (Late 1968). Inspect the gasket and diaphragm for distortion or misplacement on the carb body. The diaphragm must not be stretched or have a rippled appearance particularly within the valley portion which should be uni­form in shape (gasket should be assembled next to the body). \\ Lightly, attempt to rotate the metal diaphragm washer (riveted to the upper side of the diaphragm). If the diaphragm plate rotates freely with no drag, replace the diaphragm assembly. The diaphragm plate should not be loose. Prior to removal of the inlet lever, the initial needle seat leakage test should be performed 10-12 times with the bulb tester. Close the bulb valve. Apply pressure to the inlet to seal the vent fitting. Open the bulb valve and again apply pressure. This repetition checks the sealing of the needle in the seat insuring that it is not sticking open at the lever pin or at the groove in the needle.
     - Inspect the inlet needle lever for correct adjustment. It should be flush with the surrounding floor of the carb body. If not equipped with a shackled needle, replace with kit (27588-66). Torque seat to 45 in-lbs. ​     - Inspect the inlet needle lever for correct adjustment. It should be flush with the surrounding floor of the carb body. If not equipped with a shackled needle, replace with kit (27588-66). Torque seat to 45 in-lbs. ​
-    - Test the economizer ball check for leakage and correct operation. Using the hose end of tool (96960-68), place it over the economizer welch plug hole so that it seals off the sur­rounding area. With alternate pressure and vacuum applied by mouth, ball check should release and seal. Replace any defective parts. +    - Test the economizer ball check for leakage and correct operation. Using the hose end of tool (96960-68), place it over the economizer welch plug hole so that it seals off the sur­rounding area. With alternate pressure and vacuum applied by mouth, ball check should release and seal. Replace any defective parts. ​\\ 
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-====== Keihin Carburetor - Butterfly or Non-CV (Late 1976-1987) ====== +
- +
-===== Lean Condition Adjustments from the MoCo (1979) ===== +
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-  * During the mid 1979 model season, HD makes a recommendation to dealers for corrective measures regarding the carburetion and [[techtalk:​ih:​engctl01#​breakerless_electronic_ignition_system|ignition system]] on (1100, 1200 and 1340cc) models with emissions control design changes. They operate with leaner air/fuel mixtures and are more sensitive to carburetor mixture settings / ignition spark. ((HD Service Bulletin #M-739 dated November 3, 1978)) +
-  * For proper carburetion it is recommended to check the following items as corrective measures for irregular running and spit-back which are symptoms of an excessively lean mixture. Also check for proper ignition. +
-    * Check to see that the intake manifold seals and band clamps are installed properly. Using a squirt can with stanisol or kerosene, squirt some on these connections with the engine idling and see if there is any change (increase or decrease) in RPM which would indicate an air leak. +
-    * The air cleaner backing plate must be flat against the car­buretor flange gasket surface and the air cleaner mounting brackets must be adjusted and tightened properly per the FSM with no air leakage at the carburetor mounting flange. +
- +
-===== High Altitude Modification Kit ===== +
- +
-  * Carburetor modification kits (including jet(s) and an accelerator pump stop screw) were made available for 1200cc, 1340cc and 1000cc models to provide leaner fuel mixtures when operating at elevations above 4000 feet sea level. ((HD Service Blletin #M-730 dated June 15, 1978)) +
-    * Normally, leaner fuel/air mixtures are required for proper engine operation as the elevation above sea level increases. This high altitude kit (27096-79 for 1979 XLH (XL), XLCH, XLCR-1000) should be installed where there is evidence of a rich condition causing loss of smooth combustion, stumbling on acceleration or such other carburetor issues at high altitudes.  +
-    * The kit for Sportsters includes a #160 main jet, accelerator pump stop screw and the front down tube on the frame. +
-    * Install and adjust the acc pump stop screw to extend 1/8" past hole in lever. +
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-  * Note, any motorcycle modified for high altitude operation must be converted back to standard if operated at altitudes below 4000 feet. An overly lean condition can cause engine damage.+
  
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   * Some Welch Plug dims: [[http://​www.hubbardspring.com/​index.php/​category/​43/​cupped-plugs-and-cupped-plugs-pierced-catalog   * Some Welch Plug dims: [[http://​www.hubbardspring.com/​index.php/​category/​43/​cupped-plugs-and-cupped-plugs-pierced-catalog
 ]] ]]
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