See also in the Sportsterpedia:
Click on the diagram below to enlarge.
The list below is compilation parts list gathered from Tillotson documentation for carbs factory mounted to Sportsters.
( Click Here ) to download a PDF version of this chart. Use the reference numbers below with the diagram above.
Ref No. | HD Part# | Description | Tillotson Part No. per Carb | ||||
HD1A | HD1B | HD1C | HD1D | HD5A | |||
1 | 27760-66 | * Accelerator Pump Assembly | 013785 | 013785 | 013785 | 013785 | —- |
2 | 27759-66 | Accelerator Pump Lever | 012761 | 012761 | 012761 | 012761 | 012761 |
3 | 2540 | * Accelerator Pump Lever Screw | 06393 | 06393 | 06393 | 06393 | 06393 |
4 | 7005 | * Body Channel Cup Plug (2) | 06396 | 06396 | 06396 | 06396 | 06396 |
5 | — | * Body Channel Cup Plug (2) | 010588 | 010588 | 010588 | 010588 | 010588 |
9 | 711 | * Body Channel Welch Plug (2) | 04326 | 04326 | 04326 | 04326 | 04326 |
10 | 713 | * Body Channel Welch Plug | 013737 | 013737 | 013737 | —- | 013737 |
11 | 712 | * Body Channel Welch Plug (Choke) | 03489 | 03489 | 03489 | 03489 | —- |
12 | 27406-26 | Choke Friction Ball | 04784 | 04784 | 04784 | 04784 | —- |
13 | 27671-66 | Choke Friction Spring | 08805 | 08805 | 08805 | 08805 | —- |
16 | 27668-66 | Choke Relief Valve | 013742 | 013742 | 013742 | 013742 | —- |
17 | 27669-66 | * Choke Relief Valve Spring | 013775 | 013775 | 013775 | 013775 | —- |
19 | 27718-66 | Choke Shaft & Lever | 013777 | —- | —- | —- | —- |
27718-67 | —- | 014296 | 014296 | 014296 | |||
21 | 27661-66 | Choke Shaft Seal | 09484 | 09484 | 09484 | 09484 | —- |
22 | 27673-66 | Choke Shutter | 013741 | 013741 | 013741 | 013741 | —- |
23 | 27720-61 | * Choke Shutter Screw (2) | 08942 | 08942 | 08942 | 08942 | —- |
24 | 27716-67 | Choke Wire Connection | —- | 014294 | 014294 | 014294 | —- |
25 | 27716-55 | Choke Wire Retainer Clip | —- | 010392 | 010392 | 010392 | —- |
26 | 27716-61 | Choke Wire Connection Washer | —- | 012174 | 012174 | 012174 | —- |
27 | 993W | Choke Wire Ret. Screw | —- | 012305 | 012305 | 012305 | —- |
28 | 27806-66 | Diaphragm Gasket | 013731 | 013731 | 013731 | 013731 | —- |
27806-66R | —- | —- | —- | —- | 014120 | ||
29 | 27816-66 | * Diaphragm | 013790 | 013790 | 013790 | 013790 | —- |
27816-66R | —- | —- | —- | —- | 014248 | ||
30 | 27804-66A | Diaphragm Cover | 014871 | 014871 | 014871 | 014871 | — |
27804-66R | —- | —- | —- | —- | 014117 | ||
31 | 27812-66 | Diaphragm Cover Plug Screw | 013771 | 013771 | 013771 | 013771 | —- |
32 | 27814-66 | Diaphragm Cover Retainer Screw (6) | 010278 | 010278 | 010278 | 010278 | — |
27812-66R | — | — | — | — | 014142 | ||
33 | 27407-66 | Economiser Check Ball | 05322 | 05322 | 05322 | —- | 05322 |
43 | 27352-66 | Intermediate Mixture Screw | 013772 | 013772 | 013772 | 013772 | 013772 |
43A | 27688-66 | Idle Mixture Screw | 013787 | 013787 | 013787 | 013787 | 013787 |
44 | 27689-61 | * Intermediate Mixture Screw Spring | 011103 | 011103 | 011103 | 011103 | 011103 |
44A | 27689-61 | * Idle Mixture Screw Spring | 011103 | 011103 | 011103 | 011103 | 011103 |
45 | 27354-66 | Intermediate Mixture Screw Washer | 03114 | 03114 | 03114 | 03114 | 03114 |
46 | 27353-66 | Intermediate Mixture Screw Packing | 010511 | 010511 | 010511 | 010511 | 010511 |
47 | 27717-66 | * Idle Speed Screw | 012177 | 012177 | 012177 | 012177 | 012177 |
48 | 27747-66 | Idle Speed Screw Cup | 010050 | 010050 | 010050 | 010050 | 010050 |
49 | 27691-59 | * Idle Speed Screw Spring | 0788 | 0788 | 0788 | 0788 | 0788 |
54 | 27644-66 | Idle Speed Screw Washer | 04920 | 04920 | 04920 | 04920 | 04920 |
55 | 27740-66 | * Inlet Control Lever | 014020 | 014020 | 014020 | 014020 | 014020 |
56 | 27613-66 | * Inlet Control Lever Fulcrum Pin | 013406 | 013406 | —- | —- | —- |
27595-66 | —- | —- | 015397 | 015397 | 015397 | ||
57 | 27596-66 | * Inlet Control Lever Fulcrum Pin Screw | 013269 | 013269 | 013269 | 013269 | 013269 |
58 | 27588-66 | Inlet Needle, Seat & Gasket | 014224 | —- | —- | —- | 014224 |
27597-67 | —- | 014853 | 014853 | 014853 | |||
59A | 27746-66 | * Inlet Screen (2) | 010301 | 010301 | 010301 | 010301 | 010301 |
61 | 27598-66 | Inlet Seat Gasket | 013744 | 013744 | 013744 | 013744 | 013744 |
62 | 27599-66 | * Inlet Tension Spring | 013434 | 013434 | 013434 | 013434 | 013434 |
67 | 27745-66R | High Speed Mixture Screw | —- | —- | —- | —- | 013855 |
68 | 27834-71 | High Speed Mixture Screw Gland | —- | —- | —- | —- | 013853 |
69 | 27698-61 | High Speed Mixture Screw Gland Gasket | —- | —- | —- | —- | 0676 |
70 | 27353-66 | High Speed Mixture Screw Gland Packing | —- | —- | —- | —- | 010511 |
71 | 27689-61 | * High Speed Mixture Screw Spring | —- | —- | —- | —- | 011103 |
72 | 27354-66 | High Speed Mixture Screw Washer | —- | —- | —- | —- | 03114 |
74 | 27615-66 | Main Fuel Jet (.057) | 011394 | 011394 | 011394 | 011394 | —- |
27619-66R | Main Fuel Jet (.089) | —- | —- | —- | —- | 014313 | |
74A | 27640-66 | Main Fuel Jet Gasket | 06076 | 06076 | 06076 | 06076 | —- |
27830-71 | —- | —- | —- | —- | 013683 | ||
75 | 27704-61 | Main Fuel Jet Plug Screw | 01102 | 01102 | 01102 | 01102 | —- |
76 | 27658-66 | Nozzle Check Valve | 013789 | 013789 | 013789 | 013789 | 013789 |
78 | 27407-66 | Pump Outlet Check Ball | —- | —- | 05322 | 05322 | —- |
79 | — | Pump Outlet Check Ball Retainer | —- | —- | 012153 | 012153 | —- |
87 | 27708-66 | Throttle Shaft & Lever | 013782 | —- | —- | —- | —- |
27708-67 | —- | 014297 | 014297 | 014297 | 014297 | ||
9lA | 27706-66 | * Throttle Shaft Compression Spring | 013738 | 013738 | 013738 | 013738 | 013738 |
92 | 27707-66 | Throttle Shaft Seal (2) | 013740 | 013740 | 013740 | 013740 | 013740 |
94 | 27712-66 | * Throttle Shaft Seal Washer (2) | 013746 | 013746 | 013746 | 013746 | 013746 |
96 | 013745 | Throttle Shutter | 013745 | 013745 | 013745 | 013745 | 013745 |
97 | 2545W | * Throttle Shutter Screw (2) | 08942 | 08942 | 08942 | 08942 | 08942 |
100 | 27715-67 | Throttle Wire Connection | —- | 014225 | 014225 | 014225 | 014225 |
101 | 515 | Throttle Wire Connection Retainer Clip | —- | 0379 | 0379 | 0379 | 0379 |
102 | 6189W | Throttle Wire Connection Washer | —- | 05413 | 05413 | 05413 | 05413 |
103 | 993W | * Throttle Wire Retainer Screw | 058 | 058 | 058 | 058 | 058 |
* Gasket Set | GS-2HD | GS-2HD | GS-2HD | GS-2HD | GS-2HD | ||
Repair Parts Kit | RK-3HD | RK-3HD | RK-3HD | RK-3HD | RK-3HD |
(*) Indicates contents of Repair Parts Kit
A gallon of carburetor cleaner is very useful in cleaning out varnish from the channels and metering chamber.
It is especially useful for soaking stuck gaskets between parts and loosen the joint between them for dis-assembly.
Depending on how old or how 'stuck' the parts are, soaking for a couple hours may help to separate the old gasket in between.
Make sure to remove any rubber or plastic parts before soaking. Also check the label for safety precautions.
Parts that have been sitting for years may have to be soaked for about 24 hours or even days.
Carburetor Cleaner 4) | |
Note:
The use of wire to 'rod' out jets and orifices is discouraged in the FSM.
However, a hard wire such as a welding tip cleaner, has been known to open up stubborn areas at times.
Always use a wire smaller than the orifice cleaned so you don't widen the holes.
Doing so could create burrs or change the hole sizes.
Carb Stand:
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.
5)
6)
There are 5 known technical service bulletins related to Tillotson carbs.
Click Here to go to the Service Bulletin page in the Sportsterpedia.
You can scroll down to the following bulletins and click the “Y” next to each bulletin to download it.
Links to Welch plug sites:
The diaphragm for HD1 carbs is HD part# (27816-66).
Original P/N for a Sporty Tillotson repair parts kit 27147-66 13)
Original P/N for a Big Twin Tillotson repai parts kit 27137-66
Tillotson Carburetor repair/ refresh kit14) |
Cross reference list between HD part#s and Tillotson part#s provided by sungod of the XLForum.
HD Part# | Tillotson Part# | Description | HD Part# | Tillotson Part# | Description | |
711 | 04326 | Welch Plug | 27705-61 | 08850 | Nozzle | |
712 | 03489 | Welch Plug | 27705-66 | 014049 | Spring | |
713 | 013737 | Welch Plug | 27705-66A | 015253 | Spring | |
1065W | 08315 | Screw & Lockwasher | 27706-57 | 010519 | Spring | |
2545W | 08942 | Screw & Lockwasher | 27706-63 | 012823 | ||
2546W | 09066 | Screw | 27706-66 | 013738 | Spring | |
27119-74 | HD-14lA | Carburetor | 27707-57 | 07824 | Seal | |
27123-70R | HD-43A | Carburetor | 27707-66 | 013740 | Seal | |
27132-66R | RK-723 | Repair Kit | 27708-55 | 010444 | Shaft | |
27133-66 | GS-1HL | Gasket Kit | 27708-57 | 010844 | Shaft | |
27134-66 | RK-8HL | Repair Kit | 27708-66 | 013782 | Shaft & Lever | |
27135-63 | RK-572 | Repair Kit | 27708-67 | 014297 | Shaft & Lever | |
27135-66 | RK-3HD | Repair Kit | 27709-55 | 08597 | Clip | |
27135-66 | RK-659 | Repair Kit | 27710-55 | 010446 | Lever & Swivel | |
27135-66 | RK-660 | Repair Kit | 27710-59 | 011691 | Lever & Wire Connection | |
27137-66 | RK-764 | Repair Kit | 27711-55 | 010445 | Lever | |
27138-63 | GS-168 | Gasket Set | 27712-55 | 03804 | Washer | |
27138-66 | GS-187 | Gasket Set | 27712-66 | 013746 | Washer | |
27138-66R | GS-204 | Gasket Set | 27713-55 | 09067 | Lever | |
27138-71 | GS-223 | Gasket Set | 27713-59 | 08490 | Throttle Stop Lever | |
27139-66R | RK-771 | Repair Kit | 27714-55 | 08646 | Shutter | |
27140-71 | RK-988 | Repair Kit | 27714-61 | 012146 | Shutter | |
27143-61 | MD-119A | Carburetor | 27714-63 | 012283 | Shutter | |
27144-59 | MT-76A | Carburetor | 27714-66 | 013745 | Shutter | |
27144-63 | MD-l19B | Carburetor | 27715-55 | 010393 | Connection | |
27145-55 | MT-43A | Carburetor | 27715-59 | 011686 | Choke & Wire Conn. | |
27145-55A | MT-43B | Carburetor | 27715-61 | 012328 | Connection | |
27145-60 | MT-82A | Carburetor | 27715-66 | 013534 | Shutter | |
27150-71 | HD-77A | Carburetor | 27715-67 | 014225 | Connection | |
27150-7lA | HD-77B | Carburetor | 27716-55 | 010392 | Washer | |
27152-66 | HD-2D | Carburetor | 27716-61 | 012174 | Washer | |
27152-66A | HD-1B | Carburetor | 27716-67 | 014294 | Connection | |
27152-66B | HD-2D | Carburetor | 27717-59 | 05095 | Screw | |
27154-66R | HD-5A | Carburetor | 27717-66 | 012177 | Screw | |
27155-66 | HD-1C | Carburetor | 27718-61 | 012334 | Shaft & Lever | |
27155-66A | HD-1B | Carburetor | 27718-63 | 012806 | Shaft & Lever | |
27155-66C | HD-ID | Carburetor | 27718-66 | 013777 | Shaft & Lever | |
27158-63 | HL-139A | Carburetor | 27718-67 | 014296 | Shaft & Lever | |
27158-63 | HL-139B | Carburetor | 27719-60 | 02672 | Bushing | |
27158-63A | HL-212A | Carburetor | 27720-61 | 08942 | Screw & Lockwasher | |
27158-67 | HL-23lA | Carburetor | 27721-55 | GS-106 | Gasket Set | |
27249 | 012741 | Washer | 27721-61 | GS-116 | Gasket Set | |
27273-63 | 012825 | Lever | 27722-55 | RK-164 | Repair Kit | |
27274-67A | 015594 | Lever | 27722-59 | RK-397 | Repair Kit | |
27274-67 | 014266 | Lever | 27722-60 | RK-467 | Repair Kit | |
27276-63 | 012826 | Shaft & Lever | 27722-61 | RK-472 | Repair Kit | |
27276-66 | 014050 | Shaft | 27725-61 | 09644 | Shutter | |
27277-66R | 014297 | Shaft & Lever | 27726-61 | 09678 | Clip | |
27295-66R | RK-697 | Repair Kit | 27727-61 | 09780 | Bushing | |
27317-63 | 012284 | Jet (.043) | 27728-61 | 010079 | Lever | |
27347-69 | 012392 | Spring | 27729-61 | 012111 | Clip | |
27352-66 | 013772 | Mix. Screw | 27730-61 | 013618 | Spring | |
27353-66 | 010511 | Ring | 27730-63 | 012821 | Shaft & Lever | |
27354-66 | 03114 | Washer | 27730-66 | 014048 | Shaft & Lever | |
27407-66 | 05322 | Ball | 27730-67 | 014268 | Choke Shaft Assem. | |
27411-67R | 08304 | Gasket | 27731-61 | 011072 | Seal | |
27413-63 | 010165 | Gasket | 27731-65 | 013507 | Spring | |
27415-61 | 07903 | Gasket | 27732-61 | 01974 | Screw | |
27593-66 | 012956 | Nut | 27732-63 | 010571 | Screw | |
27595-66 | 015397 | Fulcrum Pin | 27733-61 | 0992 | Lockwasher | |
27596-66 | 013269 | Screw | 27734-62 | 010911 | Screen | |
27597-66 | 013774 | Needle & Seat | 27735-61 | 06062 | Screw & Lockwasher | |
27597-67 | 014853 | Needle & Seat | 27736-65 | 07847 | Washer | |
27598-66 | 013744 | Gasket | 27740-61 | 012321 | Mix. Screw | |
27599-66 | 013434 | Spring | 27740-63 | 010513 | Control Lever | |
27601-63 | 010529 | Gasket | 27740-66 | 014020 | Control Lever | |
27613-66 | 013406 | Pinion Pin | 27740-70R | 013589 | Inlet Lever | |
27615-66 | 011394 | Jet (.057) | 27742-61 | 012326 | Spring | |
27616-66 | 011396 | Jet (.061) | 27743-61 | 012327 | Stop Screw | |
27617-66 | 011765 | Jet (.053) | 27744-61 | 012332 | Screw | |
27618-66 | 011722 | Jet (.055) | 27745-66R | 013855 | Mix. Screw | |
27619-66 | 011395 | Jet (.059) | 27746-66 | 010301 | Screen | |
27619-66R | 014313 | Jet (.089) | 27747-66 | 010050 | Cup | |
27620-66 | 011385 | Jet (.063) | 27759-66 | 012761 | Lever | |
27622-66 | 011764 | Jet (.051) | 27760-63 | 010525 | Pump Body | |
27624-66 | 011763 | Jet (.049) | 27760-66 | 013785 | Pump Assembly | |
27640-66 | 06076 | Gasket | 27760-71 | 014992 | Shaft and Lever | |
27643-71 | 014645 | Pump Body | 27760-71A | 015959 | Shaft and Lever | |
27644-66 | 04920 | Washer | 27761-63 | 012930 | Gasket | |
27658-66 | 013789 | Check Valve | 27775-74 | 08942 | Screw & Lockwasher | |
27661-66 | 09484 | Seal | 27804-63 | 014336 | Diaphragm Cover | |
27667-71 | 015937 | Lever Assembly | 27804-66 | 013772 | Pump Body | |
27668-66 | 013742 | Relief Valve | 27804-66A | 014871 | Pump Body | |
27669-66 | 013775 | Spring | 27804-66R | 014117 | Diaphragm Cover | |
27670-55 | 05454 | Friction Pin | 27805-63 | 010527 | Strainer Cover | |
27671-66 | 08805 | Spring | 27806-63 | 012473 | Gasket | |
27672-55 | 09158 | Shaft & Lever | 27806-66 | 013731 | Gasket | |
27672-59 | 011692 | Shaft & Lever | 27806-66R | 014120 | Gasket | |
27672-61 | 012330 | Shaft & Lever | 27807-63 | 010098 | Screw & Lockwasher | |
27672-63 | 012811 | Shaft & Lever | 27808-63 | 010530 | Strainer Screen | |
27673-55 | 05088 | Shutter | 27809-63 | 012698 | Diaphragm | |
27673-66 | 013741 | Shutter | 27809-63A | 014229 | Pump Diaphragm | |
27674-63 | 012818 | Shutter | 014230 | Pump Diaphragm | ||
27674-63A | 09558 | Shutter | 27810-63 | 011428 | Washer | |
27674-66 | 014816 | Shutter | 27811-63 | 011401 | Packing | |
27675-55 | 08880 | Gasket | 27812-63 | 02232 | Plug Screw | |
27678-61 | 03311 | Plug Screw | 27812-66 | 013771 | Screw | |
27679-61 | 07896 | Plug Screw | 27812-66R | 014142 | Screw | |
27680-55 | 012144 | Float | 27813-63 | 011503 | Spring | |
27680-61 | 011294 | Float | 27814-66 | 010278 | Screw & Lockwasher | |
27680-63 | 012813 | Float | 27815-63 | 012084 | Check Valve | |
27681-55 | 011564 | Pin | 27816-63 | 012475 | Diaphragm | |
27682-55 | 010471 | Cover | 27816-66R | 014248 | Diaphragm | |
27683-55 | 08658 | Gasket | 27816-66 | 013790 | Diaphragm | |
27684-61 | 012616 | Fuel Bowl | 27817-71 | 014248 | Diaphragm | |
27685-61 | 011859 | Pinion Screw | 27818-66 | 013094 | Gasket | |
27688-55 | 08765 | Mix. Screw | 27821-63 | 012370 | Jet (.041) | |
27688-61 | 012318 | Mix. Screw | 27819-63 | 014540 | Jet (.037) | |
27688-63 | 011825 | Mix. Screw | 27820-63 | 013266 | Jet (.039) | |
27688-66 | 013787 | Mix. Screw | 27822-63 | 012284 | Jet (.043) | |
27688-71 | 015698 | Mix. Screw | 27823-66R | 011482 | Jet (.081) | |
27689-55 | 08793 | Spring | 27824-71 | 014348 | Spring | |
27689-61 | 011103 | Spring | 27825-71 | 014118 | Clip | |
27690-61 | 06569 | Gasket | 27826-71 | 014997 | Nut | |
27691-55 | 09068 | Spring | 27827-71 | 014998 | Screw | |
27691-59 | 0788 | Spring | 27828-71 | 014995 | Clamp | |
27692-55 | 08875 | Idle Tube | 27829-71 | 014999 | Bracket | |
27692-60 | 011127 | Idle Tube | 27830-71 | 013683 | Gasket | |
27692-61 | 012320 | Idle Tube | 27831-71 | 011516 | Screen | |
27693-55 | 09120 | Needle & Seat | 27832-71 | 014578 | Check Valve | |
27693-59 | 011688 | Needle & Seat | 27833-71 | 014993 | Jet (.089) | |
27693-61 | 012325 | Needle & Seat | 27833-74 | 016995 | Jet (.0635) | |
27693-63 | 012339 | Needle & Seat | 27834-71 | 013853 | Gland | |
27693-66 | 014053 | Needle & Seat | 27835-71 | 014247 | Mixture Screw | |
27694-55 | 02510 | Gasket | 27836-71 | 010079 | Lever | |
27695-66R | 013854 | Mix. Screw | 27837-71 | 014647 | Diaphragm | |
27696-63 | 010581 | Screw | 27838-71 | 014646 | Gasket | |
27696-66 | 013269 | Screw | 27839-71 | 015219 | Spring | |
27697-61 | 09112 | Packing | 27840-71 | 015218 | Screen | |
27697-66R | 013853 | Gland | 27841-71 | 015596 | Needle & Seat | |
27698-61 | 0676 | Gasket | 27842-71 | 013406 | Pinion Pin | |
27699-55 | 010347 | Mix. Screw | 27843-71 | 014239 | Mixture Screw | |
27699-59 | 07972 | Main Adj. Screw | 27844-71 | 014937 | Strainer Cover | |
27700-55 | 0705 | Packing | 27845-71 | 014644 | Diaphragm | |
27700-61 | 0702 | Gland | 27846-71 | 014643 | Gasket | |
27700-63 | 012822 | Screw | 27847-71 | 015455 | Elbow Connector | |
27701-55 | 07282 | Packing Nut | 27848-71 | 015941 | Diaphragm Cover | |
27701-61 | 0703 | Packing Nut | 27849-71 | 014120 | Gasket | |
27702-55 | 09159 | Nozzle | 27850-71 | 015010 | Shutter | |
27702-60 | 09070 | Nozzle | 27851-71 | 015052 | Shaft | |
27703-55 | 06076 | Gasket | 27852-71 | 014988 | Screw & Lockwasher | |
27704-61 | 01102 | Plug Screw | 27853-71 | 015384 | Screw | |
27704-66 | 0675 | Plug Screw | 27854-71 | 014687 | Screw & Lockwasher |