Question about 2000 Harley Davidson XL 1200 C Sportster Custom

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2003 sportster petcock replacement

How do i replace the petcock

Posted by Anonymous on

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  • Harley Davidson Master
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Hi Anonymous, for more information on your question please visit the websites below and good luck:
How To Replace The Petcock On Harley Davidson Motorcycle

Posted on Jun 01, 2015

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Posted on Jan 02, 2017

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wd4ity
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SOURCE: 2003 Harley Davidson XL 1200 C Sportster Custom

I would guess stale gasoline or fuel. Try fresh fuel in the tank. If this doesn't clear the problem, you could need to have your carburetor or fuel injection system cleaned. I'm not even sure if they put fuel injection on Sportsters since I don't work on fuel injected bikes. I mostly work on the older bikes like Panheads, Shovelheads, Evos. Not too many Sportsters but have worked on a lot of Ironhead Sportsters. Try the fuel first. It's a cheap fix. Hope it works for you. Good luck with the knee replacement. My wife had one knee replaced and it works great.

Posted on Dec 15, 2009

wd4ity
  • 4565 Answers

SOURCE: Hi My wife has a

In 1996, Harley went to a vacuum operated petcock. If you'll look on the backside, you'll see a small vacuum hose running to the petcock. The petcock is opened with vacuum being applied to a diaphragm. If this diaphragm gets a hole in it, it'll leak fuel sometime and other times will not allow fuel to go to the carb leaving you stranded with a full tank of fuel but none in the carb. You can drain the tank by loosening the large nut and using a large funnel to catch the fuel in an empty gas can. Take the two hose off, fuel and vacuum, remove the petcock. Take the four small screws out of the baskside of the petcock that holds the square plate on. Notice how the parts come out as you take the plate off slowly. Once you have the diaphragm out, hold it up to a light and gently stretch it. If you find a hole, you need to replace the diaphragm. You can get a replacement part at you local dealership. Personally, I'd rather replace the petcock with a high quality manually operated one. Of course she'll have to turn the fuel off and on old school style but you'll never have another petcock problem. I think the Pingel petcock is the top of the line. I have one on each of my personal bikes. They're pricey but they are excellent quality products. If you do this, don't forget to plug the vacuum hose. Better yet, if you can get to it, the hose has a "Y" fitting in it. Remove the hose with the "Y" fitting in it and replace it with a single hose that goes to the VOES switch.

Ride Safe
Steve

Posted on Jun 19, 2011

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Dec 22, 2012 | Harley Davidson XL 1200 C Sportster Custom...

1 Answer

Recently bought a 2003 1200 sportster. Specifically asked the previous owner about shutting off petcock when not in use. He indicated it was not necessary as it had a carb drain feature. I've put...


Your 2003 Sportster should have been equipped with a vacuum operated petcock unless someone has changed it out. This is highly likely since the factory units were very prone to problems. To drain the primary, look for a pipe plug underneath the primary at the very back underneath the area of the clutch. Refill with one quart of H-D 20W50 SYN3 engine oil or any other suitable lubricant.

Good Luck
Steve

Jul 24, 2011 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

Sportster 883 /2001 start ok running for a few minute and then shut down alredy change spark plug and coil .brought second hand ignition module but still doing the same


Check the fuel flow through your petcock. In 1996, Harley went to a vacuum operated fuel petcock. Vacuum from the engine opens the petcock, when the engine is not running and no vacuum, the petcock closes. These things give a lot of trouble. If there is a hole in the diaphragm or a cracked or loose vacuum hose, no fuel flow or insufficient fuel flow. If you have a hand operated vacuum pump, connect it to the backside of the petcock, Apply a little vacuum and see if it "holds" or if it leaks down. Disconnect the fuel line and see if the fuel flow looks sufficient. If not in either case, you'll have to take the petcock out and take the rear plate off. Take note of how the parts come out. Hold the diaphragm up to the light and gently stretch it looking for holes. If you find a hole, replace the diaphragm. Check the petcock to make sure no passageways are blocked. Personally, I suggest changing the petcock to a high quality replacement manually operated petcock. Problem solved permanently.

Good Luck
Steve

Jun 01, 2011 | 2001 Harley Davidson XL Sportster 883...

1 Answer

2003 harley davidson sportster 1200 custom. runs fine shortly then dies with spurts of fire. the light stays on and if i pull the clutch when its still running, it goes back to normal idle and responds to...


It sounds like a fuel starvation problem since it's spitting back out of the carb. Check you fuel cap to see if the vent is working. Loosen the cap and ride and see if that makes any difference.

Also, if your bike is equipped with the original vacuum equipped petcock, there could be problem with this as well. I've seen them get holes in the diaphragm and I've seen cause a vacuum leak. Check the vacuum hose and diaphragm. You'll have to remove the petcock from the tank. Personally, I'd recommend that you change the petcock to a high quality manually operated petcock like a Pingel.

Good Luck
Steve

Oct 09, 2010 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

My 2003 sportster 1200 sputtered this morning and quit. I tried to start it and it would turn over and sometime like a small backfire but would not stop. What could be the problem?


Sounds like it ran out of gas. Yeah, and I bet the fuel tank is full. Reach under the fuel tank to the petcock and pull the fuel line off. If you've still got the vacuum operated petcock, no fuel should flow out. But, if you try to start the engine, the vacuum should open the petcock and allow fuel to flow to the carb. Press the start button and watch for fuel to run out, catch the fuel in some sort of container.

If no fuel runs out, you've got a bad petcock. I've seen this at least a hundred times. Those petcocks are the worst thing Harley ever did in my opinion. You can take the petcock out of the tank, disassemble it and look for a hole in the diaphragm or you can replace it with a high quality manually operated petcock. I recommend a Pingle. They're pricey but well worth the money.

To check your diaphragm, take the four small screws out of the back of the petcock. Remove the plate watching for the small spring and needle thats under the plate. Hold the diaphragm up to the light and gently stretch it and look for a hole. If you find a hole, buy a replacement diaphragm at your local Harley dealer and reassemble your petcock.

Hopefully, this will help you fix your problem. If not, write back and give me some more information.

Good Luck
steve

Jul 29, 2010 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

Wont stay running,like its out of gas. but its not


It may indeed be out of gas. You can have a full tank of fuel and be "out of gas" in the carb. The culprit could be the vacuum operated petcock. The petcock has a diaphragm in it that is opened by engine vacuum. If that diaphragm is not functioning as it should, no gasoline gets to the carb.

To test the petcock, reach around behind it and feel for a small vacuum hose. Unplug this hose and replace it with a hose you can **** on. Using your mouth, **** on the hose with the fuel line disconnected. You should see fuel flow out of the petcock. If not, you must drain the tank by loosening the petcock and allowing the fuel to run out of the loose petcock. Use a large funnel and an empty fuel container to catch the fuel. Once the fuel tank is empty, remove the petcock. Take the plate on the back of the petcock off by removing the four small screws. You'll find a diaphragm, a small spring, and a needle. Hold the diaphragm up to the light and stretch it gently. If you find a hole in the diaphragm, replace it. Check the petcock for obstructions by blowing through it. Reassemble the petcock and test it again.

Check the hose that supplies the vacuum to the petcock. It comes from the backside of the carb and runs upwards to the VOES switch and then reduces in size and goes to the petcock. Make sure it's connected and has no holes or cracks in it.

If everything looks alright, replace the petcock, connect the hose and try to start your bike again.

These petcocks are notorious for giving problems. I always recommend that the vacuum operated petcock be replaced with a high quality manually operated petcock such as a Pingle. They're expensive and require you to manually turn the gas off like the "old school bikers" do but they won't leave you stranded out of gas with a full tank of fuel.

Good Luck
Steve

Jun 17, 2010 | 2003 Harley Davidson XLH Sportster 883...

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