Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual

7. Check float level as described in this section.
8A. On 1988 models, assemble and install the float bowl
using the following procedure:

a. Install a new O-ring onto the float bowl.
b. Install the float bowl onto the carburetor.
c. Install the retaining screws and lockwashers. Tighten

the screws securely in a crisscross pattern.

8B. On 1989-2003 models, assemble and install the float
bowl using the following procedure:

a. Insert the accelerator pump nozzle into the float

bowl. Install the O-ring onto the nozzle. See Figure
53.

b. Install the rubber boot (A, Figure 54) and O-ring (B)

onto the float bowl.

c. Connect the pump rod onto the lever assembly on the

carburetor (Figure 55).

d. Insert the pump rod through the boot on the float

bowl while installing the float bowl (Figure 56) onto
the carburetor. Then check that the pump rod is still
attached to the lever assembly as shown in Figure 57.
Check also to see if the pump rod is visible through
the hole in the pump chamber in the float bowl (Fig-
ure 58). If not, remove and reinstall the float bowl
and pump rod.

e. Install the float bowl screws and washers and tighten

securely in a crisscross pattern.

9. On 1989-2003 models, install the accelerator pump dia-
phragm assembly using the following procedure:

362

CHAPTER ELEVEN

a. Insert the accelerator pump diaphragm into the bot-

tom of the float bowl. Make sure the diaphragm (Fig-
ure 59) seats around the bowl groove evenly.

b. Install the spring (Figure 60) into the center of the ac-

celerator pump diaphragm.

c. Install the O-ring (Figure 61) into the cover passage-

way hole.

d. Align the cover assembly with the diaphragm and

bowl and install the cover assembly. Install the
screws (Figure 62) and lockwashers and tighten se-
curely.

10. Insert the jet needle (B, Figure 63) through the center
hole in the vacuum piston. Place the spring seat (A, Figure
63) over the top of the needle to secure it.
11. Align the slides on the vacuum piston with the grooves
in the carburetor bore and install the vacuum piston (Figure
64). The slides on the piston are offset, so the piston can
only be installed one way. When installing the vacuum pis-
ton, make sure the jet needle enters the needle jet.
12. Seat the outer edge of the vacuum piston into the
groove at the top of the carburetor piston chamber.
13. Insert the spring (Figure 65) into the vacuum piston so
that the end of the spring fits over the spring seat.
14. Align the free end of the spring with the carburetor top
and install the top onto the carburetor, compressing the
spring.
15. Hold the carburetor top in place and lift the vacuum
piston with a finger. The piston should move smoothly. If

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

363

the piston movement is rough or sluggish, the spring may
be improperly installed. Remove the top and reinstall the
spring.

16. Install the top carburetor screws, lockwashers and flat
washers securely.

17. Install the throttle cable bracket (A, Figure 66) onto
the carburetor so that the end of the idle speed screw en-
gages the top of the throttle cam stop (B). Hold the bracket
in place and install the bracket’s side mounting screw and
washer; tighten the screw securely. Then install the upper
bracket mounting screw (Figure 67), lockwasher and flat
washer finger-tight. Tighten the remaining carburetor cap
screw securely.

18. Align the enrichener valve needle (Figure 68) with the
needle passage in the carburetor and install the enrichener
valve. Tighten the valve nut securely.

19. Install the float bowl overflow hose and secure it with
the clamp.

Float Level Adjustment

1988-1991 models

An incorrect float level can cause flooding as well as

poor fuel economy and acceleration.

The carburetor must be removed and partially disassem-

bled for this adjustment.

1. Remove the carburetor as described in this section.

2. Remove the float bowl as described in

Disassembly

this section.

3. One-piece floats are used in the carburetor. Before
checking the float level, check that both float halves (Fig-
ure 69) are aligned at an equal height with each other. If the
float halves are not in alignment, remove the float and
check it for damage.

4. Turn the carburetor to position the float bowl as shown
in Figure 70. Measure the float height from the face of the
bowl mounting flange surface to the bottom float surface.
Do not apply pressure to the float when measuring. The
correct float height is 0.725-0.730 in. (18.4-18.5 mm).

364

CHAPTER ELEVEN

5. If the float level is incorrect, remove the float pin and
float. Bend the tab on the float hinge that contacts the fuel
valve.

6. Reinstall the float and the float pin and recheck the float
level. Repeat until the float level is correct.

7. Reinstall the float bowl as described in

Assembly

in this

setion.

8. Reinstall the carburetor as described in this chapter

1992-2003 models

An incorrect float level can cause flooding as well as

poor fuel economy and acceleration.

The carburetor must be removed and partially disassem-

bled for this adjustment.
1. Remove the carburetor as described in this chapter.
2. Remove the float bowl as described in

Disassembly

this chapter.
3. One-piece floats are used in the carburetor. Before
checking the float level, check that both float halves (Fig-
ure 71) are aligned at an equal height with each other. If the
float halves are not in alignment, remove the float and
check it for damage.
4. Place the carburetor intake spigot on a flat surface as
shown in Figure 72. This is the measuring position.
5. Tilt the carburetor 15-20

as shown in Figure 73. At this

position, the float tab will contact the fuel valve pin without
compressing the internal fuel valve spring.

NOTE

If the carburetor is tilted less than 15

or more

than 20

, the following carburetor measure-

ments will be incorrect.

6. Measure from the carburetor flange surface to the top of
the float as shown in Figure 73. When measuring float
level, do not compress the fuel valve internal spring. The
correct float level measurement is 0.413-0.453 in.
(10.5-11.5 mm).
7. If the float level is incorrect, remove the float pin and
float. Bend the tab on the float hinge that contacts the fuel
valve.
8. Reinstall the float and the float pin and recheck the float
level. Repeat until the float level is correct.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

365

0.725-0.730 in.
(18.4-18.5 mm)

Flange
face

Float

Carburetor

Float

FLOAT ADJUSTMENT

POSITION (1992-2003)

Carburetor

Float

0.413-0.453 in.
(10.5-11.5 mm)

15° to 20°

9. Reinstall the float bowl as described in

Assembly

in this

section.
10. Reinstall the carburetor as described in this chapter.

INTAKE MANIFOLD

Removal/Installation

1988-1989 models

Refer to Figure 74.
A rubber intake manifold is used on these models. A hose

clamp secures the carburetor spigot in the manifold.
1. Remove the carburetor as described in this chapter.

NOTE

It may be necessary to use a ball-end type or
shortened Allen wrench for access to the in-
take manifold bolts.

2. Remove the bolts and nuts securing the intake manifold
to the cylinder heads.

NOTE

The front and rear intake manifold flanges
are different. If the flanges are not marked
(

Figure 75

), label them with an F (front) and

R (rear) so they will be reinstalled in the cor-
rect location.

3. Remove the intake manifold, flanges and manifold seals.
4. Inspect the intake manifold.
5. Inspect the intake manifold seals (A, Figure 76) for
wear, deterioration or other damage. If damaged, replace
the seals as a set.
6. Install the flanges and seals onto the intake manifold.
Note that the seals (A, Figure 76) and flanges (B) have a ta-
pered side. Fit the seal taper into the flange taper. Be sure
the correct flange (F or R) is located at the front or rear of
the manifold.
7A. Early 1988 models are not equipped with molded
bosses on the intake manifold. On those models, position
the manifold so the parting line is 1/8 in. (3.2 mm) past the
cast boss on each flange.
7B. On late 1988-1989 models, align the molded boss on
each tube of the intake manifold with the cast boss on each
flange (Figure 77).
8. Install the intake manifold onto the cylinder head intake
ports. The slotted ends of the flanges must point to the left.
9. Make sure the front and rear seals seat squarely against
the cylinder head mating surfaces.

CAUTION

Do not attempt to align the intake manifold
after tightening the bolts. This will damage
the manifold seals.

10. Install the intake manifold mounting bolts and nuts.
Tighten the bolts and nuts to 72-120 in.-lb. (8-14 N•m).

366

CHAPTER ELEVEN

INTAKE MANIFOLD

(1989-1989 MODELS)

1. Clamp
2. Intake manifold
3. Flange
4. Seal

11. Install the carburetor as described in this chapter.

1990-2003 models

Refer to Figure 78.
An aluminum intake manifold is used on these models. The

air filter backplate secures the carburetor in the manifold.
1. Remove the carburetor as described in this chapter.

NOTE

It may be necessary to use a ball-end type or
shortened Allen wrench for access to the in-
take manifold bolts.

NOTE

On 1990 models the left side of the intake
manifold is secured by studs and nuts. On
later models, Allen bolts secure both sides of
each manifold flange.

2. Remove the bolts (A, Figure 79) and, if used, nuts se-
curing the intake manifold (B) to the cylinder heads.

NOTE

The front and rear intake manifold flanges
are different. If the flanges are not marked
(

Figure 76

), label them with an F (front) and

R (rear) so they will be reinstalled in the cor-
rect location.

3. Remove the intake manifold, flanges and manifold seals.
4. Inspect the intake manifold.
5. Inspect the intake manifold seals (A, Figure 76) for
wear, deterioration or other damage. If damaged, replace
the seals as a set.
6. Install the flanges and seals onto the intake manifold.
Note that the seals (A, Figure 76) and flanges (B) have a ta-
pered side. Fit the seal taper into the flange taper. Be sure
the correct flange (F or R) is located at the front or rear of
the manifold.
7. Install the intake manifold onto the cylinder head intake
ports. The slotted ends of the flanges must point to the left.
8. Make sure the front and rear seals seat squarely against
the cylinder head mating surfaces.
9. Tighten the intake manifold fasteners finger-tight.
10. Install the carburetor as described in this chapter.
11. Install the air filter backplate and air filter as described
in this chapter.
12. Tighten the intake manifold fasteners to 72-120 in.-lb.
(8-14 N•m).

FUEL HOSE AND CLAMPS

CAUTION

Discard removed crimp-type hose clamps. Do
not reuse removed clamps. The clamping
ability of the clamp is destroyed during re-
moval.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

367

Rubber manifold

Molded bosses

Parting line

Flange

Cast boss

INTAKE MANIFOLD

(1990-2003 MODELS)

1. Seal ring
2. Intake manifold
3. Bolt
4. Rear mounting flange
5. Seal
6. Front mounting flange

The fuel supply hose between the fuel valve and carbure-

tor is secured at the hose ends with non-reusable hose
clamps (A, Figure 80). Use diagonal pliers or other suitable
tool to separate the clamp bands, then remove the clamp.
Use hose clamp pliers (part No. HD-97087-65B or equiva-
lent) to compress the clamp bands during installation. A
screw-type hose clamp may be substituted in place of the
crimp-type hose clamp.

NOTE

End cutting pliers (B,

Figure 80

) may be mod-

ified to compress the band clamps. Make sure
to test the performance of the tool by checking
the fit and integrity of the installed clamp.

THROTTLE AND IDLE CABLES

Removal/Installation

Refer to Figure 81.

1. Remove the air filter backplate as described in this chap-
ter.
2. Before removing the cables, compare the routing of both
cables with the routing path shown in Figure 82. If neces-
sary, make a diagram of the routing path for reassembly.
3. Slide the rubber boot (Figure 83) on each cable away
from each cable adjuster.
4. Loosen the cable adjusting nuts and turn the cable ad-
justers (A and B, Figure 84) to obtain as much cable slack
as possible.
5. Remove the screws securing the upper and lower right
switch/throttle housing (Figure 85) together. Separate the
housing from the handlebar.
6. Loosen the cable locknuts at the lower switch housing.
7. Unhook the cables from the throttle grip and remove the
ferrule from the end of each cable.
8. Unscrew each cable and remove it from the lower hous-
ing assembly.
9. At the carburetor, hold the lever up with one hand and
disengage the cable end. Slip the cable out through the car-
buretor bracket. Repeat for the other cable. Figure 86
shows the throttle cables with the carburetor removed for
clarity.

10. Pass both cables through the retaining clip. On
1989-1994 models, the clip is on the fuel tank mounting
bolt (Figure 87). On 1995-2003 models, it is on the ignition
switch.

11. Remove the cables from the motorcycle.

12. Clean the throttle grip in solvent and dry thoroughly.
Check the throttle cable slots for cracks or other damage.
Replace the throttle grip if necessary.

13. The friction adjust screw is secured to the lower switch
housing with a circlip. If necessary, remove the friction
spring, circlip, spring and friction adjust screw. Check
these parts for wear or damage. Replace damaged parts. Re-
verse removal to install. Make sure the circlip seats in the
friction screw groove completely.

368

CHAPTER ELEVEN

HANDLEBAR THROTTLE

CONTROL ASSEMBLY

1. Screw
2. Upper housing
3. Lower housing
4. Ferrule
5. Control cable
6. Throttle grip
7. Friction spring
8. Spring
9. Adjusting screw

10. Adjusting nut
11. Handlebar

14. Clean the throttle area on the handlebar with solvent or
electrical contact cleaner.

15. Lightly wipe the throttle area on the handlebar with
graphite.

NOTE

The throttle cable (A,

Figure 84

) uses a

5/16-18 in. threaded cable adjuster.

16. Screw the throttle cable into the lower switch housing
and fit the ferrule onto the end of the cable. Then insert the
ferrule into the right anchor slot at the top of the throttle.

NOTE

The idle cable (B,

Figure 84

) uses a 1/4-20 in.

threaded cable adjuster.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

369

THROTTLE CABLE

ROUTING

Throttle cables

Clamp

17. Screw the idle cable into the lower switch housing and
fit the ferrule onto the end of the cable. Then insert the fer-
rule into the left anchor slot at the top of the throttle.
18. Assemble the upper and lower switch housings and
slide the throttle grip onto the handlebar. Install the housing
screws and tighten securely. Operate the throttle and make
sure both cables move in and out properly.
19. Route the throttle cables from the throttle grip to the
carburetor as shown in Figure 82 or as noted during
removal. Pass both cables through the retaining clip (Fig-
ure 87).
20. Install the throttle cable (A, Figure 84) into the shorter,
outboard cable guide on the carburetor bracket; see A, Fig-
ure 86.
21. Install the idle cable (B, Figure 84) into the longer, in-
board cable guide on the carburetor bracket; see B, Figure 86.
22. Operate the throttle grip and make sure the carburetor
throttle linkage is operating correctly and with no binding.
If operation is incorrect or there is binding, carefully check
that the cables are attached correctly and there are no tight
bends in the cables.

WARNING

Do not ride the motorcycle until the throttle
cables are properly adjusted.

23. Adjust the throttle and idle cables as described in
Chapter Three.
24. Start the engine and allow it to idle in neutral. Then
turn the handlebar from side-to-side. Do not operate the
throttle. If the engine speed increases as the handlebar as-
sembly is turned, the throttle cables are routed incorrectly.
Recheck cable routing and adjustment.

STARTING ENRICHMENT VALVE (CHOKE)

CABLE REPLACEMENT

Removal/Installation

1. Remove the air filter backplate as described in this chap-
ter.
2. Remove the enrichener bracket mounting screw (Figure
88) and allow the bracket to rest on top of the intake mani-
fold.
3. Unscrew the enrichener from the carburetor. Figure 89
shows the enrichener cable with the carburetor removed
from the motorcycel for clarity.
4. Remove the enrichener cable (Figure 90) from the mo-
torcycle.
5. Remove the bracket from the enrichener cable.
6. Reverse the removal steps to install the enrichener cable
while noting the following:

a. Align the enrichener valve needle (Figure 91) with

the needle passage in the carburetor and install the
enrichener valve. Tighten the valve nut securely.

b. Adjust the enrichener cable as described in Chapter

Three.

FUEL TANK

The fuel tank is bolted to the upper frame tube. A 3-way

fuel shutoff valve is mounted on the bottom of the tank on
the right side.

Depending on model year and state, fuel tank venting is

as follows:
1. On 1988-1991 non-California models, the filler cap is
equipped with a pressure/vacuum relief valve for fuel tank
venting.
2. On 1991 California models, refer to

Evaporative Emis-

sion Control System

in this chapter for fuel tank venting in-

formation.
3. On 1992-2003 models, the fuel tank is vented through a
standpipe installed inside the fuel tank. A hose is connected

370

CHAPTER ELEVEN

to the standpipe nozzle (Figure 92) at the bottom of the
tank. This tube is routed along the frame and connected to a
vapor valve (Figure 93) mounted to the frame and located
between the battery and oil tank.

a. On non-California models, a hose connected to the

bottom of the vapor valve connects to a fitting in the
hollow frame member.

b. On California models, a hose connected to the bottom

of the vapor valve connects to the carbon canister.

Removal/Installation

WARNING

Some fuel may spill from the fuel tank hose
during this procedure. Because gasoline is

extremely flammable and explosive, perform
this procedure away from all open flames, in-
cluding appliance pilot lights, and sparks. Do
not smoke or allow anyone to smoke in the
work area, as an explosion and fire may oc-
cur. Always work in a well-ventilated area.
Wipe up any spills immediately.

WARNING

Make sure the fuel tank vapor hoses are
routed in such a way that they cannot contact
any hot engine or exhaust component. These
hoses contain flammable vapors.

CAUTION

When removing the fuel tank in the following
procedure, keep track of all fasteners and
rubber bushings so they may be installed
into their original mounting positions. In-
correct fastener assembly can cause tank
damage.

Refer to Figure 94 or Figure 95.

1. Disconnect the negative battery cable (Chapter Twelve).
2A. On 1988-1994 models, drain the fuel tank as follows:

a. Turn the shutoff valve to off.
b. Disconnect the fuel supply hose (Figure 96) from the

fuel shutoff valve.

c. Connect a longer hose to the shutoff valve fitting and

place the open end of the hose into a gas can.

d. Turn the shutoff valve to reserve and drain the fuel

into the tank. Account for the fuel line insulator.

2B. On 1995-2003 models, drain the fuel tank as follows:

NOTE

A vacuum-operated fuel valve is installed on
all models. A hand-operated vacuum pump is
required to drain the fuel tank.

a. Turn the shutoff valve to off.
b. Connect the drain hose to the fuel valve and secure it

with a hose clamp. Insert the end of the drain hose
into a gas can.

c. Disconnect the vacuum hose from the fuel valve.
d. Connect a hand-operated vacuum pump to the fuel

valve vacuum hose fitting.

e. Turn the fuel valve to the reverse position.

CAUTION

Do not apply more vacuum than 25 in. (635 mm)
Hg or the fuel valve diaphragm will be damaged.

f. Operate the vacuum pump handle and apply a maxi-

mum of 25 in. (635 mm) Hg of vacuum. Once the
vacuum is applied, the fuel will start to flow into the
gas can.

g. When fuel stops flowing through the hose, turn the

fuel valve off and release the vacuum. Disconnect the
vacuum pump and drain hose.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

371

372

CHAPTER ELEVEN

FUEL TANK (1988-1992 MODELS)

1. Cap
2. Fuel tank
3. Bolt
4. Washer
5. Throttle cable clip
6. Ignition coil bracket
7. Horn ground wire (883 models)
8. Horn bracket (883 models)
9. Nut

10. Lockwasher (early 883 models)
11. Spacer (883 models)
12. Bolt
13. Washer

FUEL TANK (1993-2003 MODELS)

1. Bolt
2. Washer
3. Clamp

(1993-1994 models)

4. Spacer flange
5. Rubber grommet
6. Ignition coil bracket

(1993-1994 models)

7. Ignition coil bracket

(1995-2003 models)

8. Spacer

(1993-1996 models)

9. Horn bracket

(1993-1996 models)

10. Locknut
11. Fuel tank
12. Filler cap and gasket
13. Bolt
14. Washer

3. Remove the front (Figure 97) and rear (Figure 98) fuel
tank mounting fasteners.
4. Disconnect the vapor vent hose from the fitting on the
bottom of the fuel tank (Figure 92), if so equipped.
5. Remove the fuel tank.

WARNING

Store the fuel tank in a safe place, away from
open flame.

6. Drain any remaining fuel left in the tank into a gas can.
7. Installation is the reverse of removal. Note the follow-
ing:

a. Tighten the front and rear bolts to the tightening

torque specified in Table 2.

b. On all 883 models, make sure the horn does not con-

tact the frame or ignition coil bracket.

c. Reconnect the fuel hose (Figure 96) to the fuel valve

and secure it with a new hose clamp as described in

Fuel Hose And Clamps

in this chapter.

d. Refill the tank and check for leaks.

Inspection

Refer to Figure 94 or Figure 95.

1. Inspect all of the fuel and vent lines for cracks, age dete-
rioration or damage. Replace damaged lines with the same
type and size materials.
2. Check the fuel line insulator for damage.
3. Check for damaged or missing rubber dampers.
4. Remove the filler cap and inspect the inside of the tank
for rust or contamination. If there is a rust buildup inside the
tank, remove it as described in this chapter and flush the
tank to remove all rust and debris.
5. Inspect the fuel tank for leaks.

FUEL SHUTOFF VALVE

(1988-1994 MODELS)

The fuel shutoff valve is mounted on the left side of the

fuel tank. A replaceable fuel filter is mounted at the top of
the fuel shutoff valve.

Removal

Refer to Figure 99.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

373

Strainer

Fuel tank

Nut

OFF

RES

Clamp

Hose

1. Disconnect the battery negative cable (Chapter Twelve).
2. Turn the fuel valve off.
3. Disconnect the fuel supply hose (Figure 96) at the fuel
shutoff valve. Account for the fuel line insulator. Connect a
longer hose to the shutoff valve fitting and place the open
end of the hose into a gas can. Turn the shutoff valve to re-
serve and drain the fuel into the tank.
4. Loosen the shutoff valve fitting and remove the shutoff
valve from the fuel tank. Catch any gas that may leak from
the tank after the valve is removed.

Cleaning and Inspection

1. Inspect the filter mounted on top of the fuel valve. Re-
move contamination from the filter. Replace the filter if it is
damaged.

2. Install a new filter gasket before installing the filter onto
the fuel valve.

3. Remove all sealant residue from the fuel tank and fuel
valve threads.

Installation

1. Install a new filter gasket onto the fuel shutoff valve,
then install the filter.

2. Coat the fuel valve threads with pipe sealant.

3. Insert the valve into the tank. Securely tighten the valve
nut.

4. Remove the drain hose from the fuel tank and reconnect
the fuel supply hose. Secure the fuel supply hose with a new
hose clamp as described in

Fuel Hose And Clamps

in this

374

CHAPTER ELEVEN

100

EXHAUST SYSTEM (ALL MODELS EXCEPT 883R MODELS)

1. Clamp
2. Crossover heat shield
3. Rear exhaust pipe
4. Nut
5. Washer
6. Clamp
7. Snap ring
8. Gasket

9. Front exhaust pipe

10. Front heat shield
11. Stud
12. Nut
13. Front muffler
14. Bolt
15. Clamp
16. Washer

17. Nut
18. Rear muffler
19. Bolt

(1988-1991 models)

20. Muffler support
21. Washer

(1988-1991 models)

22. Nut (1988-1991 models)

23. Bolt

(1992-2003 models)

24. Nut

(1992-2003 models)

25. Rear heat shield
26. Gasket
27. Washer

chapter. Make sure the insulator is placed over the fuel sup-
ply hose before reconnecting it.

5. Refill the fuel tank and check for leaks.

FUEL SHUTOFF VALVE

(1995-2003 MODELS)

The 1995-2003 models are equipped with a vacuum-op-

erated fuel shutoff valve mounted on the left side of the fuel
tank. A replaceable fuel filter is mounted at the top of the
fuel shutoff valve.

2003 models are equipped with a three-way vacuum-op-

erated fuel shutoff valve.

To troubleshoot this valve, refer to

Fuel System

in Chap-

ter Two.

Removal

1. Disconnect the negative battery cable (Chapter
Twelve).

2. Turn the fuel shutoff valve to the off position.

3. Drain the fuel tank as described in the

Fuel Tank

in this

chapter.

4. Disconnect the vacuum hose from the fuel shutoff
valve.

5. Loosen the fuel valve nut and remove the fuel shutoff
valve from the fuel tank. Drain gasoline remaining in the
tank after valve removal.

Cleaning and Inspection

1. Inspect the filter mounted on top of the fuel valve. Re-
move contamination from the filter. Replace the filter if it is
damaged.
2. Install a new filter gasket before installing the filter onto
the fuel valve.
3. Remove all sealant residue from the fuel tank and fuel
valve threads.

Installation

1. Install a new filter gasket onto the fuel shutoff valve,
then install the filter.
2. Coat the fuel valve threads with pipe sealant.
3. Insert the fuel valve into the tank, then start the hex fit-
ting onto the fuel tank threads two turns.
4. Hold the hex fitting and start the fuel valve into the fit-
ting by turning it counterclockwise two turns.
5. Hold the fuel valve and tighten the hex fitting se-
curely.
6. Reconnect the fuel hose to the fuel shutoff valve and se-
cure it with a hose clamp. Secure the fuel supply with a new
hose clamp as described in

Fuel Hose and Clamps

in this

chapter.
7. Reconnect the vacuum hose to the valve.
8. Refill the fuel tank and check for leaks.

EXHAUST SYSTEM

(ALL MODELS

EXCEPT 883R MODELS)

Removal

Refer to Figure 100.

1. Secure the motorcycle on a suitable stand.
2. Remove the heat shields.
3. Remove the nuts and washers securing the front and
rear exhaust pipes to the cylinder heads (Figure 101, typi-
cal).
4. To remove the front muffler nut (Figure 102), perform
the following:

a. Remove the master cylinder mounting bolts (Figure

103) and lift the brake pedal upward.

b. Remove the front muffler nut (Figure 102).

5A. On 1988-1991 models, remove the nut, washer and
bolt securing the rear muffler to the muffler support
bracket.
5B. On 1992-2003 models, remove the locknut (Figure
104) and bolt attaching the rear muffler to the muffler sup-
port bracket.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

375

101

102

CAUTION

A bowed exhaust flange (

Figure 105

) may

wedge against the exhaust studs preventing
removal. If a flange is tight, remove one of the
cylinder head studs; refer to

Service Methods

in Chapter One. Replace or flatten a distorted
flange.

6. Slide the exhaust pipe flanges (Figure 106) away from
the cylinder head studs.
7. Remove the exhaust as an assembly (Figure 107).
8. Remove and discard the exhaust port gaskets (Figure
108).

NOTE

To reduce the possibility of an exhaust leak,
muffler clamps should be replaced if removed.

9. Loosen the muffler clamp bolts and remove the mufflers
from the exhaust pipes.
10. Inspect the exhaust system as described in this section.

Installation

1. Before installing the new exhaust port gaskets, remove
all carbon residue from the gasket and pipe fitting surfaces.
Wipe the port with a rag, then align the new gasket with the
port and push it into place. The new gasket should fit snugly
in the port (Figure 109). Repeat for the other exhaust port
and gasket.
2. If an exhaust stud was removed, install the stud now. Re-
fer to the

Service Method

in Chapter One.

3. Before installing the exhaust pipes, check that the snap
rings (Figure 110) holding the flanges on the exhaust pipes
fit tightly in the pipe grooves.
4. Position the exhaust pipe assembly, without mufflers, so
that the front and rear exhaust pipes fit into the front and
rear cylinder head exhaust pipes. Slide the flanges onto the
mounting studs and install a washer and nut (Figure 101)
onto each stud. Install the nuts finger-tight only.
5. Install new muffler clamps and their fasteners over the
end of the exhaust pipes as shown in Figure 100. Then slide
each muffler onto its respective exhaust pipe.

376

CHAPTER ELEVEN

103

104

106

105

107

6. Turn the front muffler so that its mounting tab engages
the stud as shown in Figure 100 and Figure 102. Install the
locknut finger-tight.
7A. On 1988-1991 models, align the rear muffler tab with
the muffler support bracket and install the bolt, washer and
nut finger-tight only.
7B. On 1992-2003 models, align the rear muffler tab with
the muffler support bracket and install the bolt and locknut
(Figure 104) finger-tight only.

NOTE

Be sure to install the rear muffler mounting
bolt assembly in the direction shown in

Fig-

ure 100

8. Tighten the exhaust fasteners in the following order to
the torque specified in Table 3:

a. Cylinder head flange nuts (Figure 101).
b. Front and rear muffler clamp nuts (Figure 111).
c. Front muffler locknut (Figure 102).
d. Rear muffler fasteners (Figure 104, typical).
e. Rear master cylinder mounting bolts (Figure 100).

9. Wipe the exhaust pipes and mufflers with a clean rag to
remove all traces of oil and grease.
10. Install the heat shields and secure with the mounting
clamps.
11. Start the engine and check for leaks. Some smoke will
be evident after starting, especially if rust penetrant was
used on the hose clamps or if oil and grease residue was not
wiped off of the exhaust pipes and mufflers.

Inspection

1. Check the exhaust pipe for cracks or spots that have
rusted through. Replace a damaged or leaking pipe.
2. Remove all rust from all pipe and muffler mating surfaces.
3. Check all of the clamps for damage or severe rusting.
Clean or repair clamps as required.
4. If the exhaust flange is distorted (Figure 105), repair or
replace it before reinstalling it. Perform the following:

a. Each exhaust flange is secured to its exhaust pipe

with a snap ring (Figure 110). Pry the ring out of its
groove and remove the flange. Discard the ring. See
Figure 112.

FUEL, EMISSION CONTROL AND EXHAUST SYSTEMS (1988-2003 MODELS)

377

109

108

110

111

112

Harley Davidson 1986-2003 XL/XLH Sportster. Service Manual - page 35