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| techtalk:ih:carb01f [2019/09/15 04:40] – [Rebuilding the Tollotson Carb] hippysmack | techtalk:ih:carb01f [2024/02/23 20:31] (current) – [Parts List] hippysmack | ||
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| [[: | [[: | ||
| - | ====== IH: Carburetor, Intake Manifold & Exhaust | + | ====== IH: Carburetor, Intake Manifold & Exhaust - Sub-01F ====== |
| \\ | \\ | ||
| ====== Rebuilding the Tillotson Carb ====== | ====== Rebuilding the Tillotson Carb ====== | ||
| + | See also in the Sportsterpedia: | ||
| + | * [[techtalk: | ||
| + | * [[techtalk: | ||
| + | * [[techtalk: | ||
| + | |||
| + | ====== Parts List ====== | ||
| + | Click on the diagram below to enlarge. \\ | ||
| + | |||
| + | {{: | ||
| + | |||
| + | \\ | ||
| + | \\ | ||
| + | |||
| + | The list below is compilation parts list gathered from Tillotson documentation for carbs factory mounted to Sportsters. \\ | ||
| + | **(** {{ pdf-bulletin: | ||
| + | |||
| + | ^{{techtalk: | ||
| + | |Ref \\ No.|HD \\ Part# | ||
| + | |::: | ||
| + | |1|27760-66|* Accelerator Pump Assembly| | ||
| + | |2|27759-66|Accelerator Pump Lever| | ||
| + | |3|2540|* Accelerator Pump Lever Screw| | ||
| + | |4|7005|* Body Channel Cup Plug (2)| 06396 | 06396 | 06396 | 06396 | 06396 | | ||
| + | |5|---|* Body Channel Cup Plug (2)| 010588 | ||
| + | |9|711|* Body Channel Welch Plug (2)| 04326 | 04326 | 04326 | 04326 | 04326 | | ||
| + | |10|713|* Body Channel Welch Plug| 013737 | ||
| + | |11|712|* Body Channel Welch \\ Plug (Choke)| | ||
| + | |12|27406-26|Choke Friction Ball| 04784 | 04784 | 04784 | 04784 | ---- | | ||
| + | |13|27671-66|Choke Friction Spring| | ||
| + | |16|27668-66|Choke Relief Valve| | ||
| + | |17|27669-66|* Choke Relief Valve Spring| | ||
| + | |19|27718-66|Choke Shaft & Lever| | ||
| + | |::: | ||
| + | |21|27661-66|Choke Shaft Seal| 09484 | 09484 | 09484 | 09484 | ---- | | ||
| + | |22|27673-66|Choke Shutter| | ||
| + | |23|27720-61|* Choke Shutter Screw (2)| 08942 | 08942 | 08942 | 08942 | ---- | | ||
| + | |24|27716-67|Choke Wire Connection| | ||
| + | |25|27716-55|Choke Wire Retainer Clip| ---- | 010392 | ||
| + | |26|27716-61|Choke Wire Connection Washer| | ||
| + | |27|993W|Choke Wire Ret. Screw| | ||
| + | |28|27806-66|Diaphragm Gasket| | ||
| + | |::: | ||
| + | |29|27816-66|* Diaphragm| | ||
| + | |::: | ||
| + | |30|27804-66A|Diaphragm Cover| | ||
| + | |::: | ||
| + | |31|27812-66|Diaphragm Cover Plug Screw| | ||
| + | |32|27814-66|Diaphragm Cover \\ Retainer Screw (6)| 010278 | ||
| + | |::: | ||
| + | |33|27407-66|Economiser Check Ball| 05322 | 05322 | 05322 | ---- | 05322 | | ||
| + | |43|27352-66|Intermediate Mixture Screw| | ||
| + | |43A|27688-66|Idle Mixture Screw| | ||
| + | |44|27689-61|* Intermediate Mixture Screw Spring| | ||
| + | |44A|27689-61|* Idle Mixture Screw Spring| | ||
| + | |45|27354-66|Intermediate Mixture Screw Washer| | ||
| + | |46|27353-66|Intermediate Mixture Screw Packing| | ||
| + | |47|27717-66|* Idle Speed Screw| | ||
| + | |48|27747-66|Idle Speed Screw Cup| 010050 | ||
| + | |49|27691-59|* Idle Speed Screw Spring| | ||
| + | |54|27644-66|Idle Speed Screw Washer| | ||
| + | |55|27740-66|* Inlet Control Lever| | ||
| + | |56|27613-66|* Inlet Control Lever \\ Fulcrum Pin| 013406 | ||
| + | |::: | ||
| + | |57|27596-66|* Inlet Control Lever \\ Fulcrum Pin Screw| | ||
| + | |58|27588-66|Inlet Needle, Seat & Gasket| | ||
| + | |::: | ||
| + | |59A|27746-66|* Inlet Screen (2)| 010301 | ||
| + | |61|27598-66|Inlet Seat Gasket| | ||
| + | |62|27599-66|* Inlet Tension Spring| | ||
| + | |67|27745-66R|High Speed Mixture Screw| | ||
| + | |68|27834-71|High Speed Mixture Screw Gland| | ||
| + | |69|27698-61|High Speed Mixture \\ Screw Gland Gasket| | ||
| + | |70|27353-66|High Speed Mixture \\ Screw Gland Packing| | ||
| + | |71|27689-61|* High Speed Mixture Screw Spring| | ||
| + | |72|27354-66|High Speed Mixture Screw Washer| | ||
| + | |74|27615-66|Main Fuel Jet (.057)| | ||
| + | |::: | ||
| + | |74A|27640-66|Main Fuel Jet Gasket| | ||
| + | |::: | ||
| + | |75|27704-61|Main Fuel Jet Plug Screw| | ||
| + | |76|27658-66|Nozzle Check Valve| | ||
| + | |78|27407-66|Pump Outlet Check Ball| ---- | ---- | 05322 | 05322 | ---- | | ||
| + | |79|---|Pump Outlet Check Ball Retainer| | ||
| + | |87|27708-66|Throttle Shaft & Lever| | ||
| + | |::: | ||
| + | |9lA|27706-66|* Throttle Shaft Compression Spring| | ||
| + | |92|27707-66|Throttle Shaft Seal (2)| 013740 | ||
| + | |94|27712-66|* Throttle Shaft Seal Washer (2)| 013746 | ||
| + | |96|013745|Throttle Shutter| | ||
| + | |97|2545W|* Throttle Shutter Screw (2)| 08942 | 08942 | 08942 | 08942 | 08942 | | ||
| + | |100|27715-67|Throttle Wire Connection| | ||
| + | |101|515|Throttle Wire \\ Connection Retainer Clip| ---- | 0379 | 0379 | 0379 | 0379 | | ||
| + | |102|6189W|Throttle Wire Connection Washer| | ||
| + | |103|993W|* Throttle Wire Retainer Screw| | ||
| + | |* Gasket Set||| | ||
| + | |Repair Parts Kit||| | ||
| + | |||
| + | |||
| + | (*) Indicates contents of Repair Parts Kit | ||
| ====== Cleaning ====== | ====== Cleaning ====== | ||
| * The general appearance of the inside of the carb is not necessarily a good indication of its condition. \\ It can look spotless and have clogged jets, or look cruddy and have clear jets. | * The general appearance of the inside of the carb is not necessarily a good indication of its condition. \\ It can look spotless and have clogged jets, or look cruddy and have clear jets. | ||
| Line 9: | Line 108: | ||
| * Examine all parts for excessive wear, damage, distortion, etc. | * Examine all parts for excessive wear, damage, distortion, etc. | ||
| * Cleaning solutions/ | * Cleaning solutions/ | ||
| - | * An overnight soak in a solution of Pinesol and water followed up with a good brush down with a toothbrush then rinse and air dry. ((http:// | + | * An overnight soak in a solution of Pinesol and water followed up with a good brush down with a toothbrush then rinse and air dry. ((http:// |
| * A 20 minute to up to a few days soak in a gallon of Gunk (or other) Carburetor Cleaner that has a basket inside for small parts and lowers in the can with a handle, rinse, air dry, use. | * A 20 minute to up to a few days soak in a gallon of Gunk (or other) Carburetor Cleaner that has a basket inside for small parts and lowers in the can with a handle, rinse, air dry, use. | ||
| - | * Soak it in mineral spirits for a few days. ((Monte03 of the XLFORUM | + | * Soak it in mineral spirits for a few days. ((Monte03 of the XLFORUM |
| - | * You can use acrylic paint thinners for cleaning up carb parts. It melts the fuel varnish right off. ((russzx6 of the XLFORUM | + | * You can use acrylic paint thinners for cleaning up carb parts. It melts the fuel varnish right off. ((russzx6 of the XLFORUM |
| * An aerosol spray carb cleaner will also work but may not loosen all of the build up in the jets or orifices in the carb body if they' | * An aerosol spray carb cleaner will also work but may not loosen all of the build up in the jets or orifices in the carb body if they' | ||
| * Blow out all holes, jets and orifices thoroughly with compressed air after cleaning. | * Blow out all holes, jets and orifices thoroughly with compressed air after cleaning. | ||
| Line 36: | Line 135: | ||
| However, this setup works better than putting the carb directly into the vice. \\ | However, this setup works better than putting the carb directly into the vice. \\ | ||
| The carb is set upright as 'in use' making adjustments more straight forward. \\ | The carb is set upright as 'in use' making adjustments more straight forward. \\ | ||
| - | {{: | + | {{: |
| {{: | {{: | ||
| ((Pic courtesy of The Doctor71 of the XLFORUM)) \\ | ((Pic courtesy of The Doctor71 of the XLFORUM)) \\ | ||
| + | |||
| + | ====== Related Service Bulletins ====== | ||
| + | There are 5 known technical service bulletins related to Tillotson carbs. \\ | ||
| + | [[techtalk: | ||
| + | You can scroll down to the following bulletins and click the " | ||
| + | * TSB# 518 dated 9-10-1965 (Includes operation, adjustments, | ||
| + | * TSB# 547 dated 10-24-1966 (Models produced after August 10, 1966 have a new carburetor inlet valve lever, needle and seat assembly.) | ||
| + | * TSB# 564 dated 1-15-1968 (Instructions included for Adjusting, Diagnosing, Disassembly, | ||
| + | * TSB# 571 dated 5-21-1968 (Tillotson carbs changed to incorporate a ball check valve in accelerating pump passage of plastic cover.) | ||
| + | * TSB# 605 dated 11-28-1969 (Addresses shipments of defective needles with incorrectly formed blunt ends instead of tapered.) | ||
| ====== Welch Plug or Expansion Plug ====== | ====== Welch Plug or Expansion Plug ====== | ||
| Line 47: | Line 156: | ||
| * Whenever a welsh plug is removed, a new one should be installed in it's place, especially since a large part of the time, removal of one means destroying or deforming it.((1959-1969 HD Sportster FSM)) | * Whenever a welsh plug is removed, a new one should be installed in it's place, especially since a large part of the time, removal of one means destroying or deforming it.((1959-1969 HD Sportster FSM)) | ||
| * Drill an 1/8" hole thru it (just deep enough to break thru to the other side) off center and pry it out with a small punch. Be careful not to drill too deep which could destroy the nozzle assembly or casting. While prying it out, be careful not to damage the casting counter-bore edges around the plug. | * Drill an 1/8" hole thru it (just deep enough to break thru to the other side) off center and pry it out with a small punch. Be careful not to drill too deep which could destroy the nozzle assembly or casting. While prying it out, be careful not to damage the casting counter-bore edges around the plug. | ||
| - | * You can also drill a small hole in it and use a small tap just big enough to start in the hole. ((snake173 of the XLFORUM | + | * You can also drill a small hole in it and use a small tap just big enough to start in the hole. ((snake173 of the XLFORUM |
| * Installation: | * Installation: | ||
| * The plug should be seated | * The plug should be seated | ||
| - | * Installation Recommendations from Hubbard Spring [[http:// | ||
| - | * Some Welch Plug dims: [[http:// | ||
| - | ===== Links,Parts and Services for Tillotson Carbs ===== | + | Links to Welch plug sites: \\ |
| - | Original P/N for a Sporty Tillotson repair parts kit 27147-66 ((rivethog of the XLFORUM | + | * [[https:// |
| + | |||
| + | ====== Diaphragm ====== | ||
| + | The diaphragm for HD1 carbs is HD part# (27816-66). \\ | ||
| + | |||
| + | {{: | ||
| + | ====== Links,Parts and Services for Tillotson Carbs ====== | ||
| + | Original P/N for a Sporty Tillotson repair parts kit 27147-66 ((rivethog of the XLFORUM | ||
| Original P/N for a Big Twin Tillotson repai parts kit 27137-66 \\ | Original P/N for a Big Twin Tillotson repai parts kit 27137-66 \\ | ||
| Line 60: | Line 174: | ||
| * [[http:// | * [[http:// | ||
| * [[http:// | * [[http:// | ||
| + | * {{ : | ||
| * Service manual for Tillotson carbs: | * Service manual for Tillotson carbs: | ||
| * [[http:// | * [[http:// | ||
| Line 71: | Line 186: | ||
| |Tillotson Carburetor repair/ refresh kit((Pic courtesy of The Doctor71 of the XLFORUM))| | |Tillotson Carburetor repair/ refresh kit((Pic courtesy of The Doctor71 of the XLFORUM))| | ||
| + | ====== Full Tillotson / HD Carb Part# Cross Reference Chart ====== | ||
| + | Cross reference list between HD part#s and Tillotson part#s provided by sungod of the XLForum. \\ | ||
| + | |||
| + | ^{{techtalk: | ||
| + | |HD Part# | ||
| + | |711|04326|Welch Plug|::: | ||
| + | |712|03489|Welch Plug|::: | ||
| + | |713|013737|Welch Plug|::: | ||
| + | |1065W|08315|Screw & Lockwasher|::: | ||
| + | |2545W|08942|Screw & Lockwasher|::: | ||
| + | |2546W|09066|Screw|::: | ||
| + | |27119-74|HD-14lA|Carburetor|::: | ||
| + | |27123-70R|HD-43A|Carburetor|::: | ||
| + | |27132-66R|RK-723|Repair Kit|::: | ||
| + | |27133-66|GS-1HL|Gasket Kit|::: | ||
| + | |27134-66|RK-8HL|Repair Kit|::: | ||
| + | |27135-63|RK-572|Repair Kit|::: | ||
| + | |27135-66|RK-3HD|Repair Kit|::: | ||
| + | |27135-66|RK-659|Repair Kit|::: | ||
| + | |27135-66|RK-660|Repair Kit|::: | ||
| + | |27137-66|RK-764|Repair Kit|::: | ||
| + | |27138-63|GS-168|Gasket Set|::: | ||
| + | |27138-66|GS-187|Gasket Set|::: | ||
| + | |27138-66R|GS-204|Gasket Set|::: | ||
| + | |27138-71|GS-223|Gasket Set|::: | ||
| + | |27139-66R|RK-771|Repair Kit|::: | ||
| + | |27140-71|RK-988|Repair Kit|::: | ||
| + | |27143-61|MD-119A|Carburetor|::: | ||
| + | |27144-59|MT-76A|Carburetor|::: | ||
| + | |27144-63|MD-l19B|Carburetor|::: | ||
| + | |27145-55|MT-43A|Carburetor|::: | ||
| + | |27145-55A|MT-43B|Carburetor|::: | ||
| + | |27145-60|MT-82A|Carburetor|::: | ||
| + | |27150-71|HD-77A|Carburetor|::: | ||
| + | |27150-7lA|HD-77B|Carburetor|::: | ||
| + | |27152-66|HD-2D|Carburetor|::: | ||
| + | |27152-66A|HD-1B|Carburetor|::: | ||
| + | |27152-66B|HD-2D|Carburetor|::: | ||
| + | |27154-66R|HD-5A|Carburetor|::: | ||
| + | |27155-66|HD-1C|Carburetor|::: | ||
| + | |27155-66A|HD-1B|Carburetor|::: | ||
| + | |27155-66C|HD-ID|Carburetor|::: | ||
| + | |27158-63|HL-139A|Carburetor|::: | ||
| + | |27158-63|HL-139B|Carburetor|::: | ||
| + | |27158-63A|HL-212A|Carburetor|::: | ||
| + | |27158-67|HL-23lA|Carburetor|::: | ||
| + | |27249|012741|Washer|::: | ||
| + | |27273-63|012825|Lever|::: | ||
| + | |27274-67A|015594|Lever|::: | ||
| + | |27274-67|014266|Lever|::: | ||
| + | |27276-63|012826|Shaft & Lever|::: | ||
| + | |27276-66|014050|Shaft|::: | ||
| + | |27277-66R|014297|Shaft & Lever|::: | ||
| + | |27295-66R|RK-697|Repair Kit|::: | ||
| + | |27317-63|012284|Jet (.043)|::: | ||
| + | |27347-69|012392|Spring|::: | ||
| + | |27352-66|013772|Mix. Screw|::: | ||
| + | |27353-66|010511|Ring|::: | ||
| + | |27354-66|03114|Washer|::: | ||
| + | |27407-66|05322|Ball|::: | ||
| + | |27411-67R|08304|Gasket|::: | ||
| + | |27413-63|010165|Gasket|::: | ||
| + | |27415-61|07903|Gasket|::: | ||
| + | |27593-66|012956|Nut|::: | ||
| + | |27595-66|015397|Fulcrum Pin|::: | ||
| + | |27596-66|013269|Screw|::: | ||
| + | |27597-66|013774|Needle & Seat|::: | ||
| + | |27597-67|014853|Needle & Seat|::: | ||
| + | |27598-66|013744|Gasket|::: | ||
| + | |27599-66|013434|Spring|::: | ||
| + | |27601-63|010529|Gasket|::: | ||
| + | |27613-66|013406|Pinion Pin|::: | ||
| + | |27615-66|011394|Jet (.057)|::: | ||
| + | |27616-66|011396|Jet (.061)|::: | ||
| + | |27617-66|011765|Jet (.053)|::: | ||
| + | |27618-66|011722|Jet (.055)|::: | ||
| + | |27619-66|011395|Jet (.059)|::: | ||
| + | |27619-66R|014313|Jet (.089)|::: | ||
| + | |27620-66|011385|Jet (.063)|::: | ||
| + | |27622-66|011764|Jet (.051)|::: | ||
| + | |27624-66|011763|Jet (.049)|::: | ||
| + | |27640-66|06076|Gasket|::: | ||
| + | |27643-71|014645|Pump Body|::: | ||
| + | |27644-66|04920|Washer|::: | ||
| + | |27658-66|013789|Check Valve|::: | ||
| + | |27661-66|09484|Seal|::: | ||
| + | |27667-71|015937|Lever Assembly|::: | ||
| + | |27668-66|013742|Relief Valve|::: | ||
| + | |27669-66|013775|Spring|::: | ||
| + | |27670-55|05454|Friction Pin|::: | ||
| + | |27671-66|08805|Spring|::: | ||
| + | |27672-55|09158|Shaft & Lever|::: | ||
| + | |27672-59|011692|Shaft & Lever|::: | ||
| + | |27672-61|012330|Shaft & Lever|::: | ||
| + | |27672-63|012811|Shaft & Lever|::: | ||
| + | |27673-55|05088|Shutter|::: | ||
| + | |27673-66|013741|Shutter|::: | ||
| + | |27674-63|012818|Shutter|::: | ||
| + | |27674-63A|09558|Shutter|::: | ||
| + | |27674-66|014816|Shutter|::: | ||
| + | |27675-55|08880|Gasket|::: | ||
| + | |27678-61|03311|Plug Screw|::: | ||
| + | |27679-61|07896|Plug Screw|::: | ||
| + | |27680-55|012144|Float|::: | ||
| + | |27680-61|011294|Float|::: | ||
| + | |27680-63|012813|Float|::: | ||
| + | |27681-55|011564|Pin|::: | ||
| + | |27682-55|010471|Cover|::: | ||
| + | |27683-55|08658|Gasket|::: | ||
| + | |27684-61|012616|Fuel Bowl|::: | ||
| + | |27685-61|011859|Pinion Screw|::: | ||
| + | |27688-55|08765|Mix. Screw|::: | ||
| + | |27688-61|012318|Mix. Screw|::: | ||
| + | |27688-63|011825|Mix. Screw|::: | ||
| + | |27688-66|013787|Mix. Screw|::: | ||
| + | |27688-71|015698|Mix. Screw|::: | ||
| + | |27689-55|08793|Spring|::: | ||
| + | |27689-61|011103|Spring|::: | ||
| + | |27690-61|06569|Gasket|::: | ||
| + | |27691-55|09068|Spring|::: | ||
| + | |27691-59|0788|Spring|::: | ||
| + | |27692-55|08875|Idle Tube|::: | ||
| + | |27692-60|011127|Idle Tube|::: | ||
| + | |27692-61|012320|Idle Tube|::: | ||
| + | |27693-55|09120|Needle & Seat|::: | ||
| + | |27693-59|011688|Needle & Seat|::: | ||
| + | |27693-61|012325|Needle & Seat|::: | ||
| + | |27693-63|012339|Needle & Seat|::: | ||
| + | |27693-66|014053|Needle & Seat|::: | ||
| + | |27694-55|02510|Gasket|::: | ||
| + | |27695-66R|013854|Mix. Screw|::: | ||
| + | |27696-63|010581|Screw|::: | ||
| + | |27696-66|013269|Screw|::: | ||
| + | |27697-61|09112|Packing|::: | ||
| + | |27697-66R|013853|Gland|::: | ||
| + | |27698-61|0676|Gasket|::: | ||
| + | |27699-55|010347|Mix. Screw|::: | ||
| + | |27699-59|07972|Main Adj. Screw|::: | ||
| + | |27700-55|0705|Packing|::: | ||
| + | |27700-61|0702|Gland|::: | ||
| + | |27700-63|012822|Screw|::: | ||
| + | |27701-55|07282|Packing Nut|::: | ||
| + | |27701-61|0703|Packing Nut|::: | ||
| + | |27702-55|09159|Nozzle|::: | ||
| + | |27702-60|09070|Nozzle|::: | ||
| + | |27703-55|06076|Gasket|::: | ||
| + | |27704-61|01102|Plug Screw|::: | ||
| + | |27704-66|0675|Plug Screw|::: | ||
| ---- | ---- | ||
