S & S C y cle, I n c.

In s tr u c tio n S h e e t 5 1 -1 0 1 0
R e v is e d 4 -4 -0 6 2 3 5 C a u s e w a y B lv d .
L a C r o s s e , W is c o n s in 5 4 6 0 3
C o p y r ig h t® , 2 0 0 2 , 2 0 0 6 P h o n e : 6 0 8 -6 2 7 -1 4 9 7 • F a x : 6 0 8 -6 2 7 -1 4 8 8
T e c h n ic a l S e r v ic e P h o n e : 6 0 8 -6 2 7 -T E C H (8 3 2 4 )
b y S & S C y c le , In c . T e c h n ic a l S e r v ic e E m a il: s s t e c h @ s s c y c le .c o m
A ll r ig h ts r e s e r v e d . P r in te d in th e U .S .A . W e b s it e : w w w .s s c y c le .c o m B e c a u s e e v e r y in d u s tr y h a s a le a d e r

In s ta lla tio n In s tr u c tio n s fo r S & S ® T W O T H R O A T C a r b u r e to r

(S e r ia l # E 1 1 9 0 & H ig h e r )
D IS C L A IM E R : IM P O R T A N T N O T IC E :
S & S p a r t s a r e d e s ig n e d f o r h ig h p e r f o r m a n c e , o f f r o a d , r a c in g S t a t e m e n t s in t h is in s t r u c t io n s h e e t p r e c e d e d b y t h e f o llo w in g w o r d s
a p p lic a t io n s a n d a r e in t e n d e d f o r t h e v e r y e x p e r ie n c e d r id e r o n ly . T h e a r e o f s p e c ia l s ig n if ic a n c e .
in s t a lla t io n o f S & S p a r t s m a y v o id o r a d v e r s e ly e f f e c t y o u r f a c t o r y W A R N IN G
w a r r a n t y . In a d d it io n s u c h in s t a lla t io n a n d u s e m a y v io la t e c e r t a in M e a n s t h e r e is t h e p o s s ib ilit y o f in ju r y t o y o u r s e lf o r o t h e r s .
f e d e r a l, s t a t e , a n d lo c a l la w s , r u le s a n d o r d in a n c e s a s w e ll a s o t h e r la w s
w h e n u s e d o n m o t o r v e h ic le s u s e d o n p u b lic h ig h w a y s , e s p e c ia lly in
C A U T IO N
s t a t e s w h e r e p o llu t io n la w s m a y a p p ly . A lw a y s c h e c k f e d e r a l, s t a t e , a n d
lo c a l la w s b e f o r e m o d if y in g y o u r m o t o r c y c le . It is t h e s o le a n d e x c lu s iv e M e a n s t h e r e is t h e p o s s ib ilit y o f d a m a g e t o t h e p a r t o r m o t o r c y c le .
r e s p o n s ib ilit y o f t h e u s e r t o d e t e r m in e t h e s u it a b ilit y o f t h e p r o d u c t f o r
h is o r h e r u s e , a n d t h e u s e r s h a ll a s s u m e a ll le g a l, p e r s o n a l in ju r y r is k a n d N O T E
lia b ilit y a n d a ll o t h e r o b lig a t io n s , d u t ie s , a n d r is k s a s s o c ia t e d t h e r e w it h . O t h e r in f o r m a t io n o f p a r t ic u la r im p o r t a n c e h a s b e e n p la c e d in it a lic t y p e .

T h e w o r d s H a r le y ®, H a r le y -D a v id s o n ®, H -D ®, S p o r t s t e r ®, E v o lu t io n ®, a n d S & S r e c o m m e n d s y o u t a k e s p e c ia l n o t ic e o f t h e s e it e m s .
a ll H -D p a r t n u m b e r s a n d m o d e l d e s ig n a t io n s a r e u s e d in r e f e r e n c e o n ly .
S & S C y c le is n o t a s s o c ia t e d w it h H a r le y -D a v id s o n , In c . W A R R A N T Y :
A ll S & S p a rts a re g u a ra n te e d to th e o r ig in a l p u r c h a s e r to b e fre e o f
S A F E IN S T A L L A T IO N A N D O P E R A T IO N R U L E S : m a n u fa c t u r in g d e f e c t s in m a t e r ia ls a n d w o r k m a n s h ip fo r a p e r io d o f
B e f o r e in s t a llin g y o u r n e w S & S p a r t it is y o u r r e s p o n s ib ilit y t o r e a d a n d t w e lv e (1 2 ) m o n th s fro m th e d a te o f p u rc h a se . M e rc h a n d is e t h a t fa ils
f o llo w t h e in s t a lla t io n a n d m a in t e n a n c e p r o c e d u r e s in t h e s e to c o n f o rm t o th e se c o n d it io n s w ill b e r e p a ir e d o r r e p la c e d a t S & S ’s
in s t r u c t io n s a n d f o llo w t h e b a s ic r u le s b e lo w f o r y o u r p e r s o n a l s a f e t y . o p t io n if t h e p a rts a re re tu rn e d to u s b y th e p u rc h a s e r w it h in th e 1 2
m o n th w a rra n t y p e r io d o r w it h in 1 0 d a y s t h e re a f t e r.
l G a s o lin e is e x t r e m e ly f la m m a b le a n d e x p lo s iv e u n d e r c e r t a in
c o n d it io n s a n d t o x ic w h e n in h a le d . D o n o t s m o k e . P e r f o r m in s t a lla t io n In t h e e v e n t w a r r a n t y s e r v ic e is r e q u ir e d , t h e o r ig in a l p u r c h a s e r m u s t
in a w e ll v e n t ila t e d a r e a a w a y f r o m o p e n f la m e s o r s p a r k s . c a ll o r w r it e S & S im m e d ia t e ly w it h t h e p r o b le m . S o m e p r o b le m s c a n b e
r e c t if ie d b y a t e le p h o n e c a ll a n d n e e d n o f u r t h e r c o u r s e o f a c t io n .
l If m o t o r c y c le h a s b e e n r u n n in g , w a it u n t il e n g in e a n d e x h a u s t p ip e s
h a v e c o o le d d o w n t o a v o id g e t t in g b u r n e d b e f o r e p e r f o r m in g a n y A p a r t t h a t is s u s p e c t o f b e in g d e f e c t iv e m u s t n o t b e r e p la c e d b y a
in s t a lla t io n s t e p s . D e a le r w it h o u t p r io r a u t h o r iz a t io n f r o m S & S . If it is d e e m e d n e c e s s a r y
f o r S & S t o m a k e a n e v a lu a t io n t o d e t e r m in e w h e t h e r t h e p a r t w a s
l B e f o r e p e r f o r m in g a n y in s t a lla t io n s t e p s d is c o n n e c t b a t t e r y t o
d e f e c t iv e , a r e t u r n a u t h o r iz a t io n n u m b e r m u s t b e o b t a in e d f r o m S & S .
e lim in a t e p o t e n t ia l s p a r k s a n d in a d v e r t e n t e n g a g e m e n t o f s t a r t e r w h ile
T h e p a r t s m u s t b e p a c k a g e d p r o p e r ly s o a s t o n o t c a u s e f u r t h e r d a m a g e
w o r k in g o n e le c t r ic a l c o m p o n e n t s .
a n d b e r e t u r n e d p r e p a id t o S & S w it h a c o p y o f t h e o r ig in a l in v o ic e o f
l R e a d in s t r u c t io n s th o ro u g h ly a n d c a r e f u lly s o a ll p ro c e d u re s a re p u r c h a s e a n d a d e t a ile d le t t e r o u t lin in g t h e n a t u r e o f t h e p r o b le m , h o w
c o m p le t e ly u n d e rsto o d b e fo re p e rfo rm in g a n y in s t a lla t io n ste p s. t h e p a r t w a s u s e d a n d t h e c ir c u m s t a n c e s a t t h e t im e o f f a ilu r e . If a f t e r
C o n ta c t S & S w it h a n y q u e s t io n s y o u m a y h a v e if a n y s t e p s a re u n c le a r a n e v a lu a t io n h a s b e e n m a d e b y S & S a n d t h e p a r t w a s f o u n d t o b e
o r a n y a b n o rm a lit ie s o c c u r d u r in g in s t a lla t io n o r o p e ra t io n o f d e f e c t iv e , r e p a ir, r e p la c e m e n t o r r e f u n d w ill b e g r a n t e d .
m o to rc y c le w it h a S & S p a rt o n it .
l C o n s u lt a n a p p r o p r ia t e s e r v ic e m a n u a l f o r y o u r m o t o r c y c le f o r c o r r e c t A D D IT IO N A L W A R R A N T Y P R O V IS IO N S :
d is a s s e m b ly a n d r e a s s e m b ly p r o c e d u r e s f o r a n y p a r t s t h a t n e e d t o b e (1 ) S & S s h a ll h a v e n o o b lig a t io n in t h e e v e n t a n S & S p a r t is m o d if ie d b y
r e m o v e d t o f a c ilit a t e in s t a lla t io n . a n y o t h e r p e r s o n o r o r g a n iz a t io n .
l U se g o o d ju d g e m e n t w h e n p e r f o r m in g in s t a lla t io n a n d o p e r a t in g (2 ) S & S sh a ll h a v e n o o b lig a t io n if a n S & S p a r t b e c o m e s d e f e c t iv e in
m o t o r c y c le . G o o d ju d g e m e n t b e g in s w it h a c le a r h e a d . D o n 't le t w h o le o r in p a rt a s a re su lt o f im p r o p e r in s t a lla t io n , im p r o p e r
a lc o h o l, d ru g s o r f a t ig u e im p a ir y o u r ju d g e m e n t . S t a r t in s t a lla t io n m a in t e n a n c e , im p r o p e r u se , a b n o r m a l o p e r a t io n , o r a n y o t h e r m is u s e
w h e n y o u a re fre sh . o r m is t re a t m e n t o f th e S & S p a rt.
l B e s u r e a ll f e d e r a l, s t a t e a n d lo c a l la w s a r e o b e y e d w it h th e (3 ) S & S s h a ll n o t b e lia b le f o r a n y c o n se q u e n t ia l o r in c id e n ta l d a m a g e s
in s t a lla t io n . r e s u lt in g f r o m th e f a ilu r e o f a n S & S p a rt, t h e b re a c h o f a n y w a r r a n t ie s ,
l F o r o p t im u m p e r f o r m a n c e a n d s a f e t y a n d t o m in im iz e p o t e n t ia l t h e f a ilu r e t o d e liv e r, d e la y in d e liv e r y , d e liv e ry in n o n -c o n f o r m in g
d a m a g e t o c a r b o r o t h e r c o m p o n e n t s , u s e a ll m o u n t in g h a r d w a r e t h a t c o n d it io n , o r f o r a n y o th e r b re a c h o f c o n tr a c t o r d u ty b e tw e e n S & S a n d
is p r o v id e d a n d f o llo w a ll in s t a lla t io n in s t r u c t io n s . a c u s t o m e r.
l M o t o r c y c le e x h a u s t f u m e s a r e t o x ic a n d p o is o n o u s a n d m u s t n o t (4 ) S & S p a r t s a r e d e s ig n e d e x c lu s iv e ly f o r u s e in H a r le y -D a v id s o n ® a n d
b e in h a le d . R u n m o t o r c y c le in a w e ll v e n t ila t e d a r e a w h e r e f u m e s o t h e r A m e r ic a n v -t w in m o t o r c y c le s . S & S s h a ll h a v e n o w a r r a n t y o r
c a n d is s ip a t e . lia b ilit y o b lig a t io n if a n S & S p a r t is u s e d in a n y o t h e r a p p lic a t io n .
 T h e S & S ®
T w o -T h r o a t s e r ie s c a rb u re to r h a s b e e n d e s ig n e d fo r a ll s iz e d is p la c e m e n t H a r le y -D a v id s o n ® S p o r ts te r ® m o d e ls
a n d b ig tw in e n g in e s . T h e c a rb u r e to r is o f th e fix e d m a in je t ty p e w ith fix e d in te rm e d ia te je ts , fix e d in te r m e d ia te a ir b le e d s
a n d a n a d ju s ta b le id le m ix tu re s c re w . T h e c a rb u re to r h a s tw o in d iv id u a l 1 5/8" th r o a ts , e a c h o f w h ic h s u p p lie s a c y lin d e r
th ro u g h a s p e c ia l m a n ifo ld w ith s e p a r a te in d u c tio n tr a c ts . T h e c a rb u re to r u tiliz e s a n a c c e le r a to r p u m p to im p r o v e th r o ttlin g
re s p o n s e a n d a c o n v e n tio n a l c h o k e to a id in c o ld w e a th e r s ta r tin g .

S h o v e lh e a d In s ta lla tio n S p o rts te r ®

T h e S & S T w o - T h r o a t s e r ie s
fo llo w in g ite m s :
O n e c a rb u re to r.
O n e a ir c le a n e r w ith m o u n tin g b
O n e in ta k e m a n ifo ld , in s u la to r b
O n e fu e l lin e a n d tw o c la m p s .
T w o e x tr a s e ts m a in je ts .
T w o e x tr a s e ts in te r m e d ia te a ir
O n e e x tr a s e ts in te r m e d ia te je ts
O n e b o w l o v e r flo w h o s e .
c a r b u r e to r k it c o n ta in s
ra c k e t.
lo c k , g a s k e ts & b o lts .
b le e d s .
. S p o r ts te r ® m o d e ls , a b r a c k e t is fu r n is h e d th a t b o lts to
M o d e l In s ta lla tio n
th e A . S p o rts te r ®
a n d B ig T w in In s ta lla tio n
1 . T h e o ld c a r b u r e to r a n d m a n ifo ld m u s t b e r e m o v e d
a n d th e m a n ifo ld s u p p lie d w ith th e k it in s ta lle d . If th e
c a r b u r e to r is to b e u s e d o n a k n u c k le h e a d o r
p a n h e a d , a b r a c k e t is fu r n is h e d th a t b o lts to th e
c e n te r c r a n k c a s e s tu d a n d th e b o tto m fr o n t m a n ifo ld
b o lt. W h e n th is b r a c k e t is u s e d , th e b o tto m fr o n t
m a n ifo ld b o lt s u p p lie d is 1/8" lo n g e r a n d m u s t b e u s e d
in th e b o tto m fr o n t h o le o n ly . F o r in s ta lla tio n o n
th e fr o n t in ta k e c a m s tu d a n d th e a ir c le a n e r b a c k
p la te . O n s h o v e lh e a d s , a b r a c k e t th a t b o lts to th e
fr o n t c y lin d e r r o c k e r b o x c o v e r a n d th e b a c k p la te is
u s e d . A fte r th e m a n ifo ld is in s ta lle d , te m p o r a r ily b o lt
th e c a r b u r e to r in p la c e .

2 . A tw o c a b le " p u ll- p u ll" ty p e th r o ttle h a n d le a s s e m b ly

s h o u ld b e u s e d w ith th e T w o -T h ro a t c a rb u re to r. T h is
S & S c a rb u re to r is fitte d w ith a n a c c e le r a to r p u m p ,
a n d b e c a u s e o f th e a d d itio n a l m e c h a n ic a l p u m p
lin k a g e , th e th r o ttle a r m a s s e m b ly h a s p r o v is io n s fo r
th e tw o c a b le s y s te m to in s u r e a p o s itiv e o n -o ff
th r o ttle m o v e m e n t.

2
 N O T E - A th in c o a tin g o f lig h t g re a s e s h o u ld b e a p p lie d to
W A R N IN G
th e th r o ttle a r m c a m , P a r t # 1 1 -2 2 4 8 , w h e r e it c o n ta c ts th e
W e d o n o t re c o m m e n d th e u s e o f th is c a r b u r e to r w ith
tra n s fe r a rm , P a rt # 1 1 -2 2 7 7 , to in s u r e m in im iz e d fr ic tio n
th e s in g le c a b le th r o ttle a s s e m b ly . In th e in te r e s t o f
a n d s m o o th th r o ttle o p e r a tio n . T h is g r e a s e is n e c e s s a r y
o p e r a to r s a fe ty , w e s tr o n g ly u r g e in s ta lla tio n o f a tw o -
o n ly fo r th e Ia s t tw o w e e k s o r s o o f o p e r a tio n u n til a
c a b le th r o ttle . T h e 1 9 8 1 a n d la te r H a r le y -D a v id s o n ®
s m o o th w e a r p a tte r n is e s ta b lis h e d . D o n o t lu b r ic a te th e
th r o ttle h a n d le a s s e m b ly c a n b e a d a p te d fo r u s e , o r if
p u m p p u s h ro d , P a rt # 1 1 -2 2 6 7
o n e c h o o s e s , S & S ® C y c le , In c . c a n p r o v id e o r
r e a s o n a b ly p r ic e a h ig h q u a lity tw o c a b le a s s e m b ly w ith
e x tr a lo n g 4 8 " c a b le s . (C o m p le te S & S tw o -c a b le th r o ttle 3 . A fte r in s ta llin g th e th r o ttle a s s e m b ly , b o lt
a s s e m b ly is P a r t # 1 1 -0 2 7 9 ). th e c a r b u r e to r in p la c e u s in g th e a lle n h e a d
b o lts p r o v id e d .
a . T h e s to c k th r o ttle o n 1 9 8 1 a n d la te r m o d e ls
c a n b e a d a p te d b y s o ld e r in g th e la s t 1 1/2 o f N O T E - F o r in s ta lla tio n o n b ig tw in s , th e s to c k w ir e fu e l
in n e r c a b le b e fo r e c u ttin g th e b a ll o r b a r r e l lin e b r a c k e t s h o u ld b e u s e d to p o s itio n th e fu e l lin e
fittin g o ff th e e n d . T h e s o ld e r in g is d o n e to b e tw e e n th e c y lin d e r s .
p r e v e n t th e s tr a n d s fr o m s e p a r a tin g . O n c e
th is o p e r a tio n is d o n e , r e m o v e th e c a r b u r e to r 4 . T h e fu e l lin e s u p p lie d s h o u ld b e u s e d in p la c e o f
a n d fe e d th e c a b le s th r o u g h th e a p p r o p r ia te th e s to c k lin e . F o r S p o rts te r® m o d e ls , th e lin e is
b o s s e s o n th e c a r b u r e to r. T h e c a b le w ith th e b e n t s h a r p ly to th e re a r o f th e b ik e o v e r th e
la r g e r d ia m e te r o u te r h o u s in g is u s e d to c a rb u re to r a n d th e n a r o u n d to th e in le t fittin g o n th e
c lo s e th e th r o ttle a n d s h o u ld b e p o s itio n e d in b o w l. S e c u r e th e lin e o n b o th e n d s w ith th e
th e b r a c k e te d h o u s in g , P a r t # 1 1 - 2 2 3 9 , w h ic h c la m p s . T h e fu e l lin e o n b ig tw in s c a n n o r m a lly b e
is a tta c h e d to th e b o w l. W h e n r o ta tin g th e ro u te d b e tw e e n th e c y lin d e r s . C h e c k o r le a k s
th r o ttle h a n d le c o u n te r c lo c k w is e , lo o k in g a t b e fo r e s ta r tin g th e e n g in e .
th e e n d o f th e h a n d le b a r, th e th r o ttle w ill
o p e n if th e c a b le s a r e c o r r e c tly r o u te d . A little
fr e e p la y s h o u ld b e le ft in b o th c a b le s w h e n W A R N IN G
tig h te n in g th e th r o ttle a r m c a b le c la m p s e t S o m e b ik e s a r e e q u ip p e d w ith e x h a u s t s y s te m s t h a t
s c r e w s . A n y e x c e s s iv e p la y c a n b e a d ju s te d c u r v e a r o u n d th e g e a r c o v e r d ir e c tly u n d e r th e
o u t a t th e th r o ttle g r ip c a b le a d ju s te r s b e fo r e c a r b u r e to r. T h e fu e l lin e m u s t n o t to u c h th e p ip e o r
e n g in e s ta r tu p . b e p la c e d in a p o s itio n w h e r e it is e x p o s e d to
e x tr e m e h e a t.
b . If th e S & S tw o c a b le th r o ttle h a n d le a s s e m b ly
N O T E - W e s tr o n g ly s u g g e s t th a t a n in - lin e fu e l filte r b e
is u s e d , th e p r o c e d u r e fo r in s ta lla tio n is m u c h
u s e d a n d s p lic e d in to th e fu e l lin e to k e e p fo re ig n m a te r ia l
th e s a m e e x c e p t th e o u te r c a b le s a r e 4 8 " lo n g
o u t o f th is c a r b u r e to r . W ith th e s m a ll m e te r in g h o le s u s e d
a n d a r e b o th o f th e s a m e d ia m e te r. T h is
in th e in te r m e d ia te s y s te m a n d th e a c c e le ra to r p u m p
m e a n s y o u m a y h a v e to s h o rte n th e o u te r
n o z z le s , it is w is e to in s u r e a g a in s t c o n ta m in a tio n to
c a b le s if th e y a r e to o lo n g fo r y o u r p a r tic u la r
p r o v id e tr o u b le fr e e o p e r a tio n .
in s ta lla tio n D e te r m in e th e b e s t r o u tin g fo r th e
o u te r c a b le s th e n c lip th e e n d s a t th e
c a r b u r e to r o n c e y o u h a v e d e te r m in e d th e 5 . T h e T w o -T h ro a t c a rb u re to r fe a tu re s a b o w l
c o r r e c t le n g th . If y o u s h o r te n th e o u te r c a b le s , o v e r flo w s y s te m . In th e e v e n t th e r id e r fo r g e ts to
y o u m u s t a ls o s h o r te n th e in n e r c a b le s , b u t b e s h u t o ff th e fu e l p e tc o c k a n d th e n e e d le a n d s e a t
s u r e to d e te r m in e th e p r o p e r le n g th a n d a s s e m b ly s tic k s , th e e x c e s s fu e l w ill flo w o u t
r e s o ld e r th e la s t 1 - 1 1/2" o f in n e r c a b le b e fo r e th r o u g h th e o v e r flo w h o s e r a th e r th a n fill th e
c u ttin g . T h is w ill in s u r e th e c a b le s tr a n d s d o c y lin d e r s w ith fu e l. F o r S p o r ts te r ® m o d e l
n o t s e p a r a te . A p p ly a lig h t c o a t o f lu b r ic a tio n to in s ta lla tio n s , th e h o s e s h o u ld b e r o u te d b e tw e e n
th e in n e r c a b le s a n d c o m p le te th e in s ta lla tio n . th e fr o n t c y lin d e r p u s h r o d c o v e r s a n d d o w n
b e tw e e n th e c r a n k c a s e a n d g e n e r a to r. F o r b ig tw in
in s ta lla tio n s , th e h o s e s h o u ld b e r o u te d b e tw e e n
N O T E - A fte r a ll c a b le a d ju s tm e n ts a re m a d e , w o rk th e
th e r e a r c y lin d e r p u s h r o d c o v e r s a n d d o w n
th r o ttle s e v e r a l tim e s w h ile tu r n in g th e h a n d le b a r s to
b e tw e e n th e c r a n k c a s e a n d tr a n s m is s io n .
e x tr e m e r ig h t a n d le ft b e fo re e n g in e s ta r tu p to b e s u r e th e
th r o ttle is s n a p p in g o ff a n d c lo s in g s h u t a ll th e w a y . If th e
th r o ttle fa ils to s n a p s h u t o r c lo s e a ll th e w a y , d e te r m in e
th e c a u s e a n d c o rre c t b e fo re e n g in e s ta r tu p .

3
 7 . S p e c ia l in s tr u c tio n s fo r e n g in e s e q u ip p e d w ith
W A R N IN G b r e a th e r v e n t lin e to th e a ir c le a n e r.
R e m e m b e r, h o w e v e r , th e b o w l o v e r flo w s y s te m is a
s a fe ty a id o n ly , a n d d o e s n o t m e a n y o u d o n o t h a v e to
tu rn o ff t h e f u e l p e tc o c k . A lw a y s tu rn o ff th e fu e l a . S & S ® a ir c le a n e rs h a v e a s p e c ia l b o s s c a s t in to
p e tc o c k w h e n th e e n g in e is n o t r u n n in g . th e a ir c le a n e r b a c k p la te d e s ig n e d e s p e c ia lly
fo r th is v e n t. T h e b a c k p la te s h o u ld b e d r ille d
6 . W ith th e fu e l lin e in p la c e , th e a ir c le a n e r b a c k p la te a n d ta p p e d fo r a 1/8" p ip e n ip p le . T h is c a n b e
a n d m o u n tin g b r a c k e t c a n b e in s ta lle d . p ro c u re d a t m o s t a n y h a rd w a re s to re . A fte r th e
a ir c le a n e r b a c k p la te m o d ific a tio n is d o n e , th e
v e n t lin e s h o u ld b e s e c u r e d w ith a c la m p .
N O T E - B e fo r e in s ta llin g th e a ir c le a n e r b a c k p la te , P a r t
# 1 7 - 0 2 8 0 , b e s u r e a n y fla s h is r e m o v e d fr o m th e fo r m e d
h o le s , e s p e c ia lly th e b o w l v e n t h o le w h ic h is p o s itio n e d B . S ta r tin g P r o c e d u r e
b e tw e e n th e a ir h o r n s ju s t b e lo w th e m id d le to p m o u n tin g
s c r e w h o le , a n d th e s m a ll d r a in h o le p o s itio n e d n e a r th e T h is c a r b u r e to r h a s a c o n v e n tio n a l c h o k e ty p e s ta r tin g
m id d le b o tto m o f th e b a c k p la te . T h e b o w l v e n t h o le m e c h a n is m . It h a s a te n s io n s p r in g , P a r t # 1 1 - 2 1 4 4 , th a t
m a tc h e s u p w ith a h o le in th e c a r b u r e to r b o d y . If th is h o le c o n s ta n tly a p p lie s p r e s s u r e a g a in s t th e c h o k e le v e r,
is b lo c k e d o r r e s tr ic te d , th e c a r b u r e to r w ill n o t r u n p r o p e r ly . P a r t # 1 1 - 2 2 4 6 , s o th a t it w ill r e m a in in p o s itio n o n c e
s e t. T h e c h o k e p la te s , P a r t # 1 1 - 2 2 7 3 , a r e fu lly c lo s e d
a . T h e S p o rts te r ®
m o d e l b r a c k e t b o lts to th e w h e n th e le v e r is p u lle d u p to th e s to p . T h e S & S T w o -
fr o n t in ta k e c a m c a g e s tu d a n d to th e fro n t T h r o a t c a r b u r e to r a ls o h a s a n a c c e le r a to r p u m p w h ic h
d ie - c a s t h o le in th e a ir c le a n e r b a c k p la te . w ill s q u ir t a s tr e a m o f fu e l d ir e c tly in to e a c h m a n ifo ld
T h e s h o v e lh e a d b r a c k e t b o lts to th e h o le in o p e n in g w h e n th e th r o ttle is o p e n e d q u ic k ly .
th e fro n t ro c k e r b o x c o v e r ju s t to th e r e a r o f
th e fr o n t in ta k e p u s h r o d a n d th e d ie c a s t h o le
1 . C o ld S ta r ts
in th e b a c k p la te w h ic h is p o s itio n e d c lo s e r to
th e fr o n t a ir h o rn .
a . O n e m a y u s e th e a c c e le r a to r p u m p to p r im e a
c o ld e n g in e r a th e r th a n th e fu ll c h o k e m e th o d .
b . B e fo re fin a l tig h te n in g o f th e m a n ifo ld c la m p s
W a it fo r 1 0 s e c o n d s a fte r tu r n in g o n th e fu e l
a n d m o u n tin g b r a c k e t, v is u a lly c h e c k th e
p e tc o c k a n d th e n p r im e th e e n g in e b y g iv in g
m o to r c y c le fro m th e fr o n t to in s u r e th e c a rb u re to r
tw o q u ic k w id e o p e n th r o ttle m o v e m e n ts . T h e n
is h o r iz o n ta l w h e n th e b ik e is h e ld u p r ig h t.
k ic k w ith th e c h o k e in th e 2/3 c lo s e d p o s itio n
a n d th e th r o ttle s lig h tly o p e n e d . B u t b e c a r e fu l
c . I m m e r s e th e fo a m p o r tio n o f th e a ir c le a n e r a s it is e a s y to flo o d th e e n g in e w ith th e
e le m e n t in a lig h t w e ig h t e n g in e o il a n d s q u e e z e a c c e le r a to r p u m p . If y o u th in k th e e n g in e is
o u t. B e fo r e fin a l a s s e m b ly o f th e a ir c le a n e r, flo o d e d , o p e n th e th r o ttle s lo w ly to th e w id e
c h e c k th e n e e d le a n d s e a t fo r p o s s ib le le a k a g e . o p e n p o s itio n . B y o p e n in g th e th r o ttle s lo w ly
H o ld th e m o to r c y c le le v e l a n d tu r n th e fu e l th e p u m p is n o t a c tu a te d . A ls o o p e n th e c h o k e
p e tc o c k o n . If g a s d o e s n o t le a k o u t o f th e e n d o f a n d th e n k ic k th r o u g h u n til th e e n g in e s ta r ts o r
th e c a r b u r e to r b o w l o v e r flo w h o s e a fte r 1 0 th e flo o d e d c o n d itio n is c le a n e d o u t.
s e c o n d s , th e e le m e n t a n d a ir c le a n e r c o v e r c a n
b e in s ta lle d . T h e c h r o m e w ir e m e s h s c r e e n m u s t
b . D u r in g o u r e x t e n s iv e te s t in g w ith th is
b e b e n t to a s m o o th c u r v e a n d in s e r te d in th e
c a rb u re to r, w e e v e n tu a lly g o t to th e p o in t
fr o n t o f th e a ir c le a n e r c o v e r. If th e n e e d le a n d
w h e re w e r a r e ly u s e d th e c h o k e , n o rm a lly
s e a t d o n o t h o ld , th e b o w l s h o u ld b e r e m o v e d
a c c o m p lis h in g m o s t c o ld s ta r ts b y p r im in g w ith
a n d c h e c k e d . S e e th e " G e n e r a l In fo r m a tio n "
th e p u m p o n ly .
s e c tio n o f th e s e in s tr u c tio n s fo r d e ta ils .

c . M o to r s w ill r e a c t d iffe r e n tly d u e to th e ty p e o f

c a m s o r p ip e s , e tc . a n d y o u w ill h a v e to
e x p e r im e n t w ith y o u r p a r tic u la r b ik e u n til y o u
fin d th e b e s t s ta r tin g p ro c e d u re fo r y o u r o w n
s e t o f c ir c u m s ta n c e s .

4
 2 . H o t S ta rts
C A U T IO N
N e v e r c lo s e th e id le m ix tu r e s c r e w tig h tly a s d a m a g e to
1 . H o t s ta r tin g d o e s n o t n o r m a lly re q u ir e th e u s e th e n e e d le a n d s e a tin g a r e a in th e c a r b u r e to r b o d y m a y
o f th e c h o k e o r p u m p p r im in g . S ta r tin g is r e s u lt. T h e th r o ttle s to p e n g in e R P M a d ju s tm e n t s c r e w
u s u a lly a c c o m p lis h e d b y tu r n in g o n th e ig n itio n lo c a te d o n th e th r o ttle a r m , P a r t # 1 1 -2 2 4 8 , is in itia lly
a n d k ic k in g w ith th e th r o ttle c lo s e d . s e t b y h o ld in g th e th r o ttle c lo s e d a n d tu r n in g th e
s c r e w u n til it c o n ta c ts th e th r o ttle a r m s to p b o s s . A t
3 . E le c tr ic S ta r t M o d e l t h is p o in t it is t u r n e d a n a d d it io n a l 1/2 t u r n c lo c k w is e .

a . C lo s e th e c h o k e h a lfw a y , tu r n o n th e ig n itio n , b . S ta r t th e e n g in e a n d w a r m it u p to o p e r a tin g

a n d w ith th e th ro ttle s lig h tly c ra c k e d e n g a g e te m p e r a tu r e . A d ju s t th e e n g in e R P M to a s lo w
th e s ta rte r. A fte r th e e n g in e s ta rts , o p e n th e id le , a p p r o x im a te ly 8 0 0 R P M . T h e n tu r n th e
c h o k e a n d w o rk th e th r o ttle s lig h tly u n til th e id le m ix tu r e s c r e w in , le a n in g it, u n til th e
e n g in e w ill id le . e n g in e s ta r ts to d ie . N e x t, tu r n th e s c r e w b a c k
o u t, r ic h e n in g it, u n til it s ta r ts to d ie . A p o s itio n
a b o u t h a lfw a y b e tw e e n th e s e p o in ts , o r a
T r o u b le S h o o tin g T ip s s e ttin g o f a b o u t 1/2 a tu r n o u t fr o m th e le a n s id e
o f th e r a n g e is th e c o r r e c t s e ttin g . F r o m th e
E n g in e w ill n o t s ta r t: fu lly c lo s e d p o s itio n th is w o u ld b e
a p p r o x im a te ly 2 to 3 tu r n s . T h e n r e s e t th e
l F u e l s u p p ly e m p ty o r r e s tr ic te d . th r o ttle s to p s c r e w to g iv e fin a l d e s ir e d R P M
l W e a k o r n o s p a r k - d is c h a r g e d b a tte r y o r fa u lty id le s p e e d . Id le s p e e d s w ill v a r y a c c o r d in g to
m a g n e to . th e in d iv id u a l a n d th e u s e to w h ic h th e
m a c h in e is p u t.
N O T E - W e d o n o t re c o m m e n d th o u s e o f m a g n e to s .
N O T E : W h e n e v e r a n in te r m e d ia te s y s te m je ttin g c h a n g e
l P lu g g a p to o w id e - w e u s e .0 2 0 to .0 2 2 p lu g g a p is m a d e , th e id le m ix tu r e s c r e w s h o u ld b e r e a d ju s te d w ith
o n o u r p o in t ty p e ig n itio n e n g in e s . th e e n g in e h o t.
l Im p r o p e r ig n itio n tim in g .
l T ig h t ta p p e t a d ju s tm e n t. T r o u b le S h o o tin g T ip s
l Im p r o p e r id le m ix tu r e a n d /o r e n g in e R P M s e ttin g .
l In te r m e d ia te je ts o r a ir b le e d s lo o s e . E n g in e w ill n o t id le .
l Im p r o p e r d ia g n o s is o f a r ic h o r le a n m ix tu r e
c o n d itio n . If th e e n g in e fir e s in th e c a r b , it is to o l Im p r o p e r id le m ix tu r e a n d /o r e n g in e R P M s e ttin g .
le a n a n d m u s t b e r e - p r im e d . D o n o t c o n tin u e to l In ta k e m a n ifo ld a ir le a k .
k ic k th e e n g in e o v e r w ith th e s w itc h o n u n til it is
l S tic k y tim in g a u to m a tic a d v a n c e m e c h a n is m .
r e p r im e d . If th e r e is n o r e s p o n s e a fte r th r e e k ic k s
o r if it p o p s in th e e x h a u s t p ip e s , it is to o r ic h .
N O T E - O n th o s e e n g in e s w ith s p r in g lo a d e d m e c h a n ic a l
L e a v e th e s w itc h o n a n d o p e n th e th r o ttle w id e
a d v a n c e ig n itio n s y s te m s , w e p e r fo r m a s s ta n d a r d
o p e n a n d k ic k u n til it fir e s .
p r o c e d u r e to e a c h o f o u r m o to r s , th e fo llo w in g
m o d ific a tio n : R e m o v e a n d c le a n th e tim in g a d v a n c e
C . A d ju s tin g th e C a r b u r e to r
m e c h a n is m . R e b e n d th e s m a ll s p r in g s w h ic h r e ta r d th e
tim in g b y s h o r te n in g e a c h s p r in g 1/16" o n b o th e n d s to
1 . Id le C ir c u it in c r e a s e s p r in g te n s io n . T h is w ill in s u r e th e e n g in e r e ta r d s
p r o p e r ly a n d r e tu r n s to a s m o o th , lo w id le . W e h a v e fo u n d
a . T h e id le m ix tu re s c re w , P a rt # 1 1 -2 3 5 4 , is th a t th is n o r m a lly c u r e s th o s e c o n d itio n s w h e r e th e m o to r
in itia lly s e t d u r in g a s s e m b ly to 2 1/2 tu r n s o u t w ill n o t a lw a y s r e tu r n to a lo w id le a n d in s te a d s o m e tim e s
fro m th e fu lly c lo s e d p o s itio n . C h e c k th is a n d id le s a t a h ig h e r s p e e d , u p to 1 4 0 0 - 1 6 0 0 R P M .
re s e t th e s c re w to 2 1/2 tu r n s b e fo re a tte m p tin g
to s ta rt th e e n g in e . l F o r e ig n m a te r ia l o b s tr u c tin g g a s flo w to id le c ir c u it.
l In c o r r e c t in te r m e d ia te je ttin g .

5
 2 . In te r m e d ia te S y s te m e . H ig h e r a ltitu d e o r h o t, d ry w e a th e r m a y r e q u ir e
U p to 3 0 0 0 R P M o r 5 5 -6 0 M P H a le a n e r m ix tu r e ( s m a lle r in te r m e d ia te je ts
a n d /o r b ig g e r a ir b le e d s ) w h ile lo w e r a ltitu d e ,
c o ld w e a th e r, o r a w a r m a n d h u m id c lim a te
a . F o r n o r m a l r id in g c o n d itio n s , th e in te r m e d ia te
m a y r e q u ir e a r ic h e r m ix tu r e ( la r g e r
r a n g e is u s e d th e m o s t. T h e r e fo r e , c lo s e
in te r m e d ia te je ts a n d /o r s m a lle r a ir b le e d s ) to
a tte n tio n m u s t b e p a id to je ttin g th e m id - r a n g e
d ia l th e s y s te m in p r o p e r ly .
to a c h ie v e o p tim u m p e r fo r m a n c e a n d g a s
m ile a g e . O n c e th e e n g in e is w a r m e d u p a n d
th e id le m ix tu r e a n d e n g in e R P M s c r e w s s e t, f. W e h a v e ru n a :
th e b ik e m u s t b e r o a d te s te d . T h e in te r m e d ia te 1 . 9 0 0 c c H a r le y - D a v id s o n ® S p o r ts te r ® m o d e l
r a n g e is u s e d fr o m r ig h t o ff id le u p to w ith th e .0 2 9 - .0 4 6 in te r m e d ia te c o m b in a tio n .
a p p r o x im a te ly 3 0 0 0 - 3 5 0 0 R P M o r 5 0 to 6 0 2 . 1 0 0 0 c c S p o r ts te r ® m o d e l w ith .0 3 0 - .0 4 6 .
M P H d e p e n d in g o n g e a r in g . T h r o ttlin g 3 . S to c k 7 4 " p a n h e a d w ith .0 2 9 - .0 4 6 .
c h a r a c te r is tic s c a n b e c h e c k e d b y s lo w ly
4 . 8 0 " s h o v e lh e a d w ith .0 3 0 - .0 4 6 .
o p e n in g th e th r o ttle ( s o a s to n o t e n e r g iz e th e
a c c e le r a to r p u m p ) a fte r m a in ta in in g a s te a d y 5 . 9 8 " s h o v e lh e a d w ith th e .0 3 3 -.0 4 6
s p e e d . T h is c a n b e d o n e a t s e v e r a l R P M le v e ls c o m b in a tio n .
o r s p e e d s o f 3 0 , 4 0 , a n d 5 0 M P H . If p o p p in g o r
s p ittin g o c c u r s in th e a ir c le a n e r, th is is a le a n 3 . M a in J e t
c o n d itio n a n d s h o u ld b e c o r r e c te d . A n o th e r F ro m 3 0 0 0 R P M o r 5 5 -6 0 M P H a n d u p :
in d ic a tio n o f a le a n in te r m e d ia te s y s te m c a n b e
n o tic e d b y fe e lin g a " fla t" o r " la b o r in g " a . M a in je ttin g is b e s t d e te r m in e d b y te s tin g a t th e
c o n d itio n w h ile c r u is in g a t 5 5 to 6 0 M P H , r ig h t d r a g s tr ip . J e ttin g s h o u ld a lw a y s b e d o n e a t
a t th e to p o f th e in te r m e d ia te r a n g e . o p e r a tin g te m p e r a tu r e . A fte r a r u n is m a d e , th e
e n g in e R P M a n d fin a l s p e e d s h o u ld b e n o te d .
N O T E - A s m e n tio n e d e a r lie r, it is e x tr e m e ly c r itic a l th a t A s e c o n d r u n s h o u ld b e m a d e w ith a .0 0 4
th e id le m ix tu r e s c r e w a n d th ro ttle s to p s c r e w b e a d ju s te d la r g e r, r ic h e r, je t in s ta lle d . A g a in , R P M a n d
w ith a h o t m o to r. T h e id le w ill e ffe c t th e in te r m e d ia te fin a l s p e e d is n o te d . T h is p r o c e d u r e s h o u ld b e
s y s te m a n d if it is n o t a d ju s te d p ro p e r ly , o n e w ill n o t g e t a c o n tin u e d u n til th e m ile s p e r h o u r fa lls o ff. T h e
tru e re a d in g a s to th e p e rfo rm a n c e o f th e in te r m e d ia te . m a in je t s h o u ld th e n b e m a d e s m a lle r ( le a n e r )
to g a in th e b e s t m a x im u m R P M a n d M P H .
b . If th e in te r m e d ia te s y s te m is to o r ic h , it m a y W h e n m a k in g th e s e r u n s , d o n o t s tr iv e fo r E T s ,
s h o w u p b y p o p p in g in th e p ip e s , a " lo p e " o r b u t fo r c o n s is te n t m ile s p e r h o u r. W e h a v e
m is s a t lo w e r R P M s , o r a m is s o r s tu tte r a t fo u n d th a t m a x im u m m ile s p e r h o u r a n d R P M
tr a n s itio n , a b o u t 3 0 0 0 to 3 5 0 0 R P M s , e s p e c ia lly h a v e b e e n th e b e s t in d ic a to r s o f p r o p e r je ttin g .
in lo w g e a r u n d e r re d u c e d lo a d c o n d itio n s .
b . If th e e n g in e is b u tto n e d o ff a fte r e a c h r u n , th e
c . T o le a n th e in te r m e d ia te , in s ta ll a s m a lle r s e t o f s p a r k p lu g s m a y b e in s p e c te d fo r r ic h n e s s o r
in te r m e d ia te je ts , P a rt # 1 1 -7 3 0 0 . O n e m a y a ls o le a n n e s s . P lu g c o lo r th o u g h is n o t a lw a y s a
m a k e s u b tle c h a n g e s b y b le e d in g in m o r e a ir b y g o o d in d ic a tio n o f c a r b je ttin g o n q u a r te r m ile
in s ta llin g la r g e r a ir b le e d s , P a r t # 1 1 -7 3 2 0 . te s ts . W e h a v e fo u n d th a t d iffe r e n t b r a n d s o f
g a s o lin e , g a s o lin e a d d itiv e s , e n g in e h e a t ( d u e
d . T o r ic h e n th e in te r m e d ia te s y s te m , in s ta ll a to ig n itio n tim in g ) , a n d ty p e o f p lu g s a n d h e a t
la r g e r p a ir o f in te r m e d ia te je ts a n d /o r s m a lle r r a n g e u s e d a lte r r e a d in g s d r a s tic a lly . N e w
a ir b le e d s p lu g s u s u a lly r e q u ir e th e tim e in v o lv e d in a
r o a d te s t to p r o p e r ly d e v e lo p th e p lu g c o lo r. It
is b e s t to u s e a p r o v e n c o m b in a tio n a n d to
N O T E - A p r o p e r ly je tte d in te r m e d ia te s y s te m w ill a c t le a n c o n s u lt th e s p a r k p lu g m a n u fa c tu r e r fo r m o r e
( c o u g h o r s p it) w h e n th e e n g in e is c o ld a n d w ill r e q u ir e r id in g s p e c ific in fo r m a tio n if o n e d e s ir e s to b e c o m e
a fe w m ile s to w a r m th e e n g in e to o p e r a tin g te m p e r a tu r e . p r o fic ie n t a t p lu g r e a d in g . C h a m p io n R a c in g
D iv is io n h a s a v e r y in fo r m a tiv e b o o k le t. F o r
d e ta ils , w r ite :
C h a m p io n S p a r k P lu g C o m p a n y
P .O . B o x 9 1 0
T o le d o , O h io 4 3 6 0 1

6
c . If m a in je ttin g te s ts c a n n o t b e c o n d u c te d a t th e T r o u b le S h o o tin g T ip s
d r a g s tr ip , th e " R P M in g " m e th o d c a n b e u s e d . E n g in e w ill n o t r u n a t s te a d y s p e e d :
T h is p r o c e d u r e w o u ld b e to r u n th e b ik e
th r o u g h th e g e a r s n o tin g h o w q u ic k ly a n d
l R e s tr ic tio n in fu e l s u p p ly s y s te m - g a s ta n k v e n t
s m o o th ly th e e n g in e r e a c h e s th e R P M le v e l
p lu g g e d , g a s p e tc o c k to o s m a ll ( s to c k H a r le y -
w h e r e g e a r s a r e s h ifte d . U n d e r r a c in g
D a v id s o n ® p e tc o c k is a d e q u a te , b u t m ig h t r e q u ir e
c o n d itio n s th is le v e l is w h e r e h o r s e p o w e r
r u n n in g o n r e s e r v e to p r o v id e a d e q u a te s u p p ly fo r
p e a k s a n d b e g in s to ta p e r o ff. T h e m a in je t th a t
b ig in c h e n g in e s ) , n e e d le a n d s e a t a s s e m b ly n o t
m a k e s th e e n g in e p u ll th e s tr o n g e s t o r R P M
w o r k in g p r o p e r ly .
th r o u g h th e g e a r s b e s t is th e c o r r e c t o n e . O u r
e x p e r ie n c e is th a t a je t a b o u t .0 0 6 s m a lle r l F a u lty ig n itio n s y s te m - fo u le d p lu g s , w o r n p o in ts ,
( le a n e r ) in s iz e w ill m a k e th e e n g in e p o p a n d d e fe c tiv e c o il.
s p u tte r o r " b r e a k u p " in th e c a r b u r e to r a n d d ie . l In c o r r e c t in te r m e d ia te a n d /o r h ig h s p e e d je ttin g .
A je t a b o u t .0 0 6 la r g e r ( r ic h e r ) w ill m a k e th e l F o r e ig n m a te r ia l in a ir a n d /o r g a s p a s s a g e w a y in
e n g in e r u n fla t a n d s lu g g is h o r " b lu b b e r " . c a r b c a u s in g flo w r e s tr ic tio n . R e m o v e a n d c le a n
in te r m e d ia te je ts a n d b le e d s .
d . O n c e r ta in e n g in e s , p a r tic u la r ly S p o rts te r® l V a lv e tr a in d e fe c t - b a d v a lv e s , s tic k y v a lv e s ,
m o d e ls , a n in d ic a tio n o f a r ic h m a in je t b a d o r b r o k e n s p r in g s , im p r o p e r c le a r a n c e s fo r
c o n d itio n w ill s o m e tim e s a p p e a r a s a s lig h t h ig h lift c a m s .
m is s a t tr a n s itio n fr o m th e in te r m e d ia te s y s te m l B o w l v e n t o b s tru c te d .
to th e m a in je ts .
E n g in e w ill n o t R P M :
e . If th is o c c u r s w h ile r u n n in g h a r d th r o u g h th e l R e s tr ic tio n in fu e l s y s te m .
g e a r s a t 3 0 0 0 - 4 0 0 0 R P M , tr y s m a lle r m a in je ts . l F a u lty ig n itio n s y s te m .
l In c o r r e c t h ig h s p e e d je ttin g .
f. W e h a v e ru n : l F o r e ig n m a te r ia l in a ir a n d /o r g a s p a s s a g e w a y s in
1 . 9 0 0 c c S p o rts te r ® m o d e ls w ith .0 5 0 m a in je ts . c a r b c a u s in g flo w r e s tr ic tio n .
2 . 1 0 0 0 c c S p o r ts te r® m o d e ls w it h . 0 5 2 's . l T o o m u c h g e a r. ( N o t e n o u g h h o r s e p o w e r to p u ll
3 . S to c k 7 4 " p a n h e a d w ith . 0 5 0 's . th e g e a r in g .)
4 . 8 0 " s h o v e lh e a d w ith .0 5 2 's . l V a lv e tr a in d e fe c t.
5 . 9 8 " s h o v e lh e a d w ith .0 5 6 's . l B o w l v e n t o b s tru c te d .

g . T h e a b o v e w a s w a r m w e a th e r je ttin g a t 6 0 0 to
1 0 0 0 fe e t a b o v e s e a le v e l e le v a tio n .

h . O b v io u s ly , lik e th e in te r m e d ia te je ttin g , th e
m a in je t r e q u ir e m e n ts w ill v a r y s o m e w h a t
w ith c o n d itio n s .

7
 D . G e n e r a l In fo r m a tio n T o p
1 . D o n o t c h ro m e th e c a rb u re to r a s e x te n s iv e
d a m a g e w ill r e s u lt.

B e v e ls m u s t
2 . T h e c a r b u r e to r h a s s e v e r a l d r ille d p a s s a g e s th a t b e a t a n g le s
a r e p e r m a n e n tly s e a le d w ith p lu g s . D o n o t a tte m p t s h o w n w h e n
to r e m o v e th e s e p lu g s . in s ta llin g
th r o ttle p la te .
3 . D o n o t o v e r - tig h te n th e id le m ix tu r e s c r e w ,
in te r m e d ia te je ts , o r in te r m e d ia te a ir b le e d s .
S id e V ie w
4 . T h e th ro ttle p la te s . P a rt # 1 1 -2 2 5 5 , a n d th r o ttle
s h a ft, P a rt # 1 1 -2 2 5 4 , s h o u ld b e c h e c k e d a n n u a lly F ig u r e A
fo r s ig n s o f w e a r. R e p la c e , if n e c e s s a ry . If th e y a re 8 . C a m s a n d e x h a u s t s y s te m s m a k e s o m e e n g in e s
re m o v e d , b e s u re th a t th e th r o ttle p la te s a r e d iffic u lt to c a r b u r a te . A c o m b in a tio n o f c a m o v e r la p
r e in s ta lle d c o r r e c tly . S e e F ig u r e A . a n d b a c k p r e s s u r e , o r la c k o f b a c k p r e s s u r e w ill
c a u s e m ix tu r e d ilu tio n a t c e r ta in e n g in e R P M s .
5 . If th e th r o ttle a rm , P a r t # 1 1 - 2 2 4 8 , is r e m o v e d fr o m T h is d ilu tio n w ill c a u s e e n g in e r o u g h n e s s o r
th e th r o ttle s h a ft, it m u s t b e r e in s ta lle d in th e w id e m is fir in g w h e n th e e n g in e is h e ld in th is r a n g e . T o
o p e n p o s itio n w ith th e b u tte r fly a t 9 0 ° to th e fu lly a tte m p t to c a r b u r a te fo r th is c o n d itio n u s u a lly
c lo s e d p o s itio n . S e e F ig u r e B . d e s tr o y s th e c a r b u r e tio n o v e r th e r e s t o f th e r a n g e .
It is b e s t u n d e r th e s e c o n d itio n s to c h a n g e th e c a m
6 . T h e c o r r e c t flo a t le v e l a d ju s tm e n t is s h o w n b e lo w in a n d /o r th e e x h a u s t s y s te m .
F ig u r e C . W h e n th e m o to rc y c le is n o t r u n n in g , th e
fu e l s h u to ff v a lv e s h o u ld a lw a y s b e tu rn e d o f. In th e 9 . S & S ® h a s fo u n d th a t s to c k h e a d p ip e s e q u ip p e d
e v e n t fu e l ru n s o u t o f th e b o w l o v e r flo w h o s e , w ith a g o o d q u a lity s lip - o n m u ffle r w ill p r o v id e a
r e m o v e th e b o w l a s s e m b ly a n d in s p e c t th e flo a t a n d n ic e a m o u n t o f h o r s e p o w e r a n d to r q u e .
n e e d le a n d s e a t a s s e m b ly to b e s u r e it d o e s n ’t b in d
a n d th e flo a t le v e l is p r o p e r ly s e t. S e e F ig u r e C .
1 0 . U s e a fu e l filte r to k e e p d ir t o u t o f th is c a r b u re to r.
W ith th e s m a ll m e te r in g h o le s u s e d in th e
7 . If a n a ir c le a n e r o th e r th a n o u r s m u s t b e u s e d , in te r m e d ia te s y s te m a n d th e a c c e le r a to r p u m p
m a k e s u r e th e b o w l v e n t h o le in th e in le t e n d o f th e n o z z le s , it is w is e to in s u r e a g a in s t c o n ta m in a tio n
c a r b u r e to r is n o t c o v e r e d a n d s e a le d o ff. to p r o v id e tr o u b le fr e e o p e r a tio n .

T h r o ttle p la te
h o r iz o n ta l

T h r o ttle a r m
a g a in s t s to p

T h r o ttle a r m B o w l is s h o w n u p s id e d o w n .
S id e V ie w s e t s c re w S id e V ie w

F ig u r e B F ig u r e C

8
 1 1 . F o r th o s e in v o lv e d in a n " a ll- o u t" d r a g r a c in g e ffo r t 3 . T h e id le m ix tu r e s c re w , P a r t # 1 1 - 2 3 5 4 , is lo c a te d o n
u s in g v e r y la r g e d is p la c e m e n t e n g in e s , y o u m a y th e to p o f th e c a rb u re to r. T u r n in g th e s c r e w c lo c k w is e
c o n s id e r : ( in ) , w ill le a n th e m ix tu r e . A c o u n te r c lo c k w is e m o tio n
a . R a is in g th e flo a t le v e l 1/8" ,
( o u t) , w ill r ic h e n th e m ix tu r e .
b . T o im p r o v e a ir - flo w , r e m o v in g th e c h o k e
a s s e m b ly a n d p lu g g in g th e c h o k e s h a ft h o le s 4 . T h e in te r m e d ia te je ts , P a r t # 1 1 - 7 3 0 0 , a r e a v a ila b le
in th e c a r b b o d y a s w e ll a s r u n n in g w ith o u t th e in s iz e s fr o m .0 2 8 to .0 3 4 in g r a d u a tio n s o f .0 0 1
a ir c le a n e r e le m e n t. Y o u m a y a ls o e le c t to r u n w ith .0 3 4 b e in g th e r ic h e s t. N o r m a lly , .0 2 9 to .0 3 3
th e 1 " s p a c e r b lo c k , P a rt# 1 6 -0 2 9 5 , a n d d o s iz e s a r e u s e d .
s o m e p o r tin g w o rk to th e in d u c tio n tr a c t to
fu r th e r im p r o v e a ir flo w . 5 . T h e in te r m e d ia te a ir b le e d s , P a rt # 1 1 -7 3 2 0 , a re
m a d e in s iz e s .0 2 8 , .0 3 2 , .0 3 6 , .0 4 0 , .0 4 3 , .0 4 6 ,
1 2 . In c lo s in g , r e m e m b e r th a t th is c a r b u r e to r h a s la r g e .0 5 2 , .0 5 5 , .0 5 9 , a n d .0 6 3 , w ith .0 6 3 b e in g th e
v e n tu r i c o m p a r e d to th e s to c k u n it. T h is m e a n s th a t le a n e s t. N o rm a lly b le e d s in th e m id d le o f th e s c a le
a t lo w R P M s , v e lo c ity th r o u g h th e c a r b u r e to r is w ill b e u s e d .
v e r y lo w a n d it is m o r e d iffic u lt to e n e r g iz e th e m a in
je t, p a r tic u la r ly o n s to c k d is p la c e m e n t b ig tw in o r 6 . T h e m a in je ts , P a rt # 1 1 -7 2 0 0 , a r e m a d e in
H a r le y - D a v id s o n ® S p o r ts te r ® m o d e ls . B e c a u s e o f in c r e m e n ts o f .0 0 2 a n d ra n g e in s iz e fro m .0 4 0 to
th e d e s ig n a n d w ith th e a d d itio n o f a n a c c e le r a to r .0 6 0 , w ith .0 6 0 b e in g th e r ic h e s t. T h e y c a n b e
p u m p . o n e c a n g e n e r a lly " w h a c k " th e th r o ttle o n a t c h a n g e d a fte r re m o v in g th e b o tto m b o w l p lu g s .
lo w e r R P M s a n d s till p ic k u p th e m a in je t. W ith o u r
s to c k l0 0 0 c c S p o r ts te r, w e w e r e a b le to " w h a c k it 7 . W h e n c h a n g in g a n y je ts , b e s u r e to c h a n g e in p a ir s ,
o n " a t 1 2 0 0 R P M in lo w , 1 6 0 0 R P M in s e c o n d , a s e a c h th r o a t o r " b a r r e l" h a s its o w n s e t o f je ts .
2 0 0 0 R P M in th ir d a n d 2 5 0 0 R P M in h ig h . B e lo w
th o s e R P M s , w e e ith e r d o w n - s h ifte d o r s lo w ly
r o lle d th e th r o ttle o n u n til R P M s w e r e u p s u ffic ie n tly 8 . U p o n w a r m in g th e e n g in e to n o r m a l o p e r a tin g
to p ic k u p th e m a in je t. A fte r g e ttin g y o u r p a r tic u la r te m p e ra tu re a fte r m a k in g a n y je ttin g c h a n g e s to th e
e n g in e je tte d p r o p e r ly , y o u w ill h a v e to e x p e r im e n t in te rm e d ia te s y s te m a lw a y s r e a d ju s t th e id le
w ith th e th r o ttlin g c h a r a c te r is tic s a s th is w ill v a r y m ix tu r e s c re w .
w ith d iffe r e n t m o to r c o n fig u r a tio n s .
B e lo w is a c h a r t w ith s o m e b a s ic g u id e lin e s to fo llo w w h ile
je ttin g y o u r T w o - T h r o a t c a r b u r e to r.
E . J e ttin g T ip s

S to c k M ild L a r g e
1 . U s e a fu e l filte r to in s u r e fo r e ig n m a te r ia l d o e s n o t C ID S tro k e rs E n g in e s
e n te r th is c a r b u r e to r.
B ig T w in 6 1 "-7 4 " 8 0 "-8 4 " 8 6 " & u p

2 . T h e T w o - T h r o a t h a s a n a d ju s ta b le id le m ix tu r e S p o rts te r ®
m o d e ls 5 5 "-6 1 " U p to 7 4 " 7 5 " & u p
s c r e w , fix e d in te r m e d ia te je ts , fix e d in te r m e d ia te a ir Id le M ix tu r e S c r e w 2 -3 tu rn s 2 -3 tu rn s 2 -3 tu rn s
b le e d s a n d fix e d m a in je ts .
In te r m e d ia te J e t .0 2 9 -.0 3 0 .0 3 0 -.0 3 1 .0 3 2 -.0 3 3
In te r m e d ia te B le e d .0 4 0 -.0 5 2 .0 4 0 -.0 5 2 .0 4 0 -.0 5 2
M a in J e t .0 4 6 -.0 5 4 .0 4 8 -.0 5 6 .0 5 2 -.0 6 0

9
 T w o -T h ro a t C a rb u re to r 2 4 . T ra n s fe r a rm s c re w . . . . . . . .1 1 -2 2 5 1 4 3 . C h o k e p la te . . . . . . . . . . . . . .1 1 - 2 2 7 3
R e p la c e m e n t P a r ts 2 5 . G a s k e t - p u m p c a p c o v e r . . .1 1 -2 2 5 2 4 4 . D ia p h r a g m s p r in g . . . . . . . . .1 1 -2 2 7 5
2 6 . In te r m e d ia te je t - S e e " J e ttin g C h a r t" . 4 5 . P u m p le v e r . . . . . . . . . . . . . .1 1 - 2 2 7 6
1 . C h o k e /th r o ttle p la te s c r e w 6 - 3 2 x 1/4"
2 7 . T h r o ttle s h a ft . . . . . . . . . . . . .1 1 - 2 2 5 4 4 6 . T ra n s fe r a rm . . . . . . . . . . . . .1 1 -2 2 7 7
. . . . . . . . . . . . . . . . . . . . . . .1 1 -0 0 5 5
2 8 . T h r o ttle p la te . . . . . . . . . . . . .1 1 - 2 2 5 5 4 7 . A ir c le a n e r c o v e r . . . . . . . . .1 7 -0 2 7 8
2 . Id le m ix tu r e s c r e w s p r in g . . .1 1 -2 0 5 2
2 9 . G a s k e t - m a n ifo ld . . . . . . . . .1 6 -0 2 5 6 4 8 . A ir c le a n e r e le m e n t . . . . . . .1 7 -0 2 7 9
3 . Id le m ix tu r e s c r e w . . . . . . . . .1 1 - 2 3 5 4
3 0 . C o v e r - p u m p c a p . . . . . . . . .1 1 -2 2 5 7 4 9 . B a c k p la te . . . . . . . . . . . . . . .1 7 - 0 2 8 0
4 . S e a t . . . . . . . . . . . . . . . . . . .1 1 -2 0 6 5
3 1 . " Y " m a n if o ld 5 0 . D ia p h r a g m . . . . . . . . . . . . . .1 1 -2 2 8 2
5 . M a in je t - S e e " J e ttin g C h a r t" .
A ll H a r le y -D a v id s o n ® S p o r t s t e r ® 5 1 . P u m p c a p . . . . . . . . . . . . . . . . . .N /A
6 . A ir c le a n e r c o v e r s c r e w m o d e ls . . . . . . . . . . . . . . . .1 6 -4 3 0 0
(1 0 P a c k ) . . . . . . . . . . . . . . . . .5 0 - 0 0 9 4
5 2 . L e v e r s c re w . . . . . . . . . . . . .1 1 -2 2 8 5
S h o v e ls 1 9 7 9 & e a r lie r . . . .1 6 -4 3 1 6
7 . T h r o ttle r e tu r n s p r in g . . . . . .1 1 -2 0 8 2 5 3 . O - r in g (1 0 P a c k ) . . . . . . . . . . .5 0 -8 0 9 6
3 2 . M a n ifo ld s c r e w - 2 0 x 1 3/8"
8 . B a c k p la te - b o w l s c r e w w ith lo c k w a s h e r 5 4 . B o w l . . . . . . . . . . . . . . . . . . . . . . .N /A
S h o v e l, S p o r ts te r ® m o d e ls o r P a n
1 0 - 2 4 x 5/8" (1 0 P a c k ) . . . . . . .5 0 - 0 0 6 2 (1 0 P a c k ) . . . . . . . . . . . . . . . . .5 0 - 0 1 5 3 5 5 . G a s k e t, b o w l . . . . . . . . . . . . .1 1 -2 2 8 9
9 . B o tto m p lu g . . . . . . . . . . . . .1 1 -2 0 9 0 3 3 . M a n ifo ld s c r e w - 1/4 - 2 0 x 2 " 5 6 . A ir c le a n e r s c r e e n . . . . . . . .1 7 -0 2 9 0
1 0 . N e e d le . . . . . . . . . . . . . . . . .1 1 -2 0 9 5 F o r u s e w ith s p a c e r b lo c k . . . . . .N /A 5 7 . In s u la to r b lo c k . . . . . . . . . . .1 6 -0 2 9 1
1 1 . S u p p o r t b r a c k e t b o lt . . . . . . . . . .N /A 3 4 . O v o r flo w h o s e . . . . . . . . . . . .1 9 - 0 2 6 2 5 8 . A ir c le a n e r s u p p o r t b r a c k e t
1 2 . S u p p o r t b r a c k e t lo c k n u t . . . . . . .N /A 3 5 . M a n if o ld s c r e w - 1 / 4 - 2 0 x 1 1 / 2 " S h o v e lh e a d . . . . . . . . . . . . . . . . . 1 7 - 0 2 9 2

1 3 . C h o k e a rm s c re w . . . . . . . . .1 1 -2 1 4 3 B o tto m fr o n t o n ly fo r p a n h e a d s . .N /A 5 9 . A ir c le a n e r s u p p o r t b r a c k e t
3 6 . P a n h e a d m a n ifo ld S p o r ts te r ® m o d e ls . . . . . . . .1 7 - 0 2 9 3
1 4 . C h o k e s p r in g . . . . . . . . . . . . .1 1 - 2 1 4 4
3 7 . B e llo w s s e a l . . . . . . . . . . . . .1 1 - 2 2 6 6 6 0 . P u m p c a p s c r e w lo c k w a s h e r 8 - 3 2 x 7 /1 6 "
1 5 . C h o k e w a s h e r
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .N /A
1 6 . In te r m e d ia te a ir b le e d 3 8 . P u s h ro d - p u m p . . . . . . . . . .1 1 -2 2 6 7
6 1 . 1 " S p a c e r b lo c k ( o p tio n a l) . .1 6 -0 2 9 5
S e e " J e ttin g C h a r t" . 3 9 . F lo a t s c r e w 1 0 - 3 2 x 1
/4" . . . . .5 0 - 0 0 3 6
6 2 . A ir c le a n e r s u p p o r t b r a c k e t - p a n h e a d
1 7 . F lo a t . . . . . . . . . . . . . . . . . . . . . . .N /A 4 0 . F lo a t p in . . . . . . . . . . . . . . . .1 1 -2 2 6 9
. . . . . . . . . . . . . . . . . . . . . . .1 6 -0 2 9 6
1 8 . C a b le h o u s in g b r a c k e t . . . . .1 1 - 2 3 3 9 4 1 . A c tu a to r p in . . . . . . . . . . . . . .1 1 - 2 2 7 1
1 9 . C h o k e s h a ft . . . . . . . . . . . . . .1 1 -2 2 4 6 4 2 . B a ll c h e c k (1 0 P a c k ) . . . . . . . .5 0 -8 1 2 5
2 0 . B o d y . . . . . . . . . . . . . . . . . . .1 1 -2 2 4 7
2 1 . T h r o ttle a r m a s s e m b ly . . . . .1 1 -2 2 4 8
2 2 . S c r e w w ith lo c k w a s h e r
6 - 3 2 x 5/16 . . . . . . . . . . . . . . . . . . .N /A
2 3 . M a in d is c h a r g e tu b e . . . . . . .1 1 -2 2 5 0

1 0
 3 2
3 3 3 1
6 1

2 9
7 1 2 6
5 7
2 7 2 2 9
1 3 3 3 2
1 4
1 6
1 5 3 6
1 9
3 5
1
4 9
2 8

6 2
4 8 2 0 2 1
8 2 3
5 6 4 3 5 5 5

1 7
4 0 4 2
3 7
1 1 4 4
1 0 5 0 3 8
1 2
3 9 2 4
5 3
5 4 5 3
5 8 4 1 5 1
4 6
5 9 8
6 3 4 3 4
4 5
2 5
6 0 3 0
1 8
9
2 2
4

1 1
B e c a u s e e v e r y in d u s tr y h a s a le a d e r