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Fuel and vacuum line routing off carb

1999 Harley Sportster 1200XLH. My SM manual does not show the routing of the hoses off the carb and I want to make sure I have everything routed properly. Where can I find a routing diagram to make sure everything is proper? Thank you.

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Generally the hoses will be moulded in a certain way to ensure they have the correct clearances to prevent chafing or rubbing on other parts. If the hoses refit without having to force them on or stretch them and they don't hang down, I would think they would be in the correct position. My HD book doesn't show hose routing either.

Posted on Nov 25, 2013

Testimonial: "Thanks Steve. I think I have everything correct, but since I replaced all the lines with the non molded alternatives I just wasn't sure."

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The proper air gap is .032 to .036 depending on spark plug brand.

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SOURCE: 2004 honda crf 150 and all of the hoses are off of carb.?

Not positive but on two stroke bikes all but one of your hoses are breather and over flow hoses and are smaller than the fuel line that should come from the front left of the carb and go up to the fuel tank. the rest should come from the carb and have holders attached to the carb feed the line closest to the holder and fit it on the breather hole coming from the carb pertruding outward from the carb. there should be three or four lines and one fuel line.

Posted on Jan 30, 2009

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There is a very good one in the sservice manual available from Honda.

Posted on Jun 16, 2009

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SOURCE: need oil routing diagram for 1989 harley davidson

Little tip -The only time the oil cooler will cool is when the bike is moving and when the bike is moving you don't need the oil cooler. This is from a factory harley tech.

Posted on Jun 21, 2009

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2002 1200 Sportster vacuum line routing

Hi, Richard for this scenario you will need your service/owners manual if you can not find the first and best tool you ever bought for your Harley, despair not, for a mere $7 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below and for more specific information or questions at no charge please feel free to contact me at Good luck and have a nice day.
Vacuum Lines Routing Harley Davidson Forums
2002 1200 Sportster vacuum line routing Google Search
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Feb 03, 2017 | 2002 Harley Davidson XL 1200 S Sportster...

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How the fuel lines are attached to the tank on a 2004 Harley 1200 Sportster

Hi, Aubrey the vacuum line to the fuel valve just slides on and the fuel line is secured with a crimp clamp or hose clamp for more information about your issue and valuable "FREE" downloads that you will need please visit the websites below, and for specific information or questions, please feel free to contact me at Good luck and have a nice day.
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Jul 18, 2015 | Tank Motorcycles

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Have an ss carb e type an a single outlet pingel pepcock have a vent line from carb what do I do with the vent line

Here's S&S's manual for the Shorty Carbs (both E & G):

On page "10", it states, "Slip fuel overflow hose onto fitting on carb bowl and neatly route behind pushrod tubes. On a big twin model, hose should go toward back
of engine. On a Harley-Davidson Sportster model, hose should go toward front of engine. Exit end of overflow hose must extend down
below engine and away from exhaust pipes."

This is the only "vent" hose (actually, a fuel overflow hose) that I know of.

Aug 24, 2014 | Motorcycles

1 Answer

Yamaha roadstar 1600

One line that comes from the top LH side of carb (looking at carb w/o air cleaner) is a carb vent aprox 1/4 " hose. It connects only to the carb & hangs in a wire bracket as a vent tube. The 1/2 " vent line that goes from the valve cover on the rear cylinder goes to the spigot on the air cleaner case & vents the crankcase gases back into the intake of the carb to be burnt. Those are the only 2 lines other than the fuel line that comes from the metal pipe that crosses over to the fuel pump on the other side of bike. That fuel line connects to the carb metal fuel spigot on the side of the carb. That's fuel into carb.

Mar 26, 2014 | 2002 Yamaha Road Star

1 Answer

Won t start

Try switching to RESERVE, as it should be mechanically operated, rather than vacuum operated.

If that works, test the vacuum operation on the petcock.
You can try sucking your brains out on the vacuum line going to the petcock, or apply a vacuum with something like this:

When you do this, have a line going from the petcock to a catch can (gas can), and see if fuel flows under vacuum.

If that works, with bike running (petcock on RESERVE), pull vacuum line at petcock, put a finger over hose opening, and feel that it is drawing a vacuum.

Mar 20, 2014 | 2004 Harley Davidson XL 883 Sportster

1 Answer

How do i change the fuel line in my 2000 xl1200 C sportster ? i have a slow leak from old hoses

Turn off fuel tank petcock valve. Remove complete air filter assembly. Disconnect fuel hose from bottom of petcock(may have to cut hose clamp off and will have to replace with a regular worm screw hose clamp). Hold a rag around the end of the hose where you are pulling it off to catch and squirted fuel. You then pull hose off the carbs elbow fitting the same way you did at the other end. If hose on carb is not easy to access, you may have to pull the carb out of the rubber boot that connects the carb into the intake manifold. Replace hose with same length of new hose which is 1/4" fuel line hose. Reassemble in reverse order using the above mentioned worm screw hose clamps.

Jun 25, 2012 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

I need routing diagrams for both gas & oil lines for a 1990 HD XLH883H Sportster

Contact me directly at and I'll send you a drawing for the oil lines. The fuel line simply runs from the petcock to the carb between the cylinders. Nothing special about it's routing.


Aug 12, 2011 | Harley Davidson XLH Sportster 883 Hugger...

1 Answer

Hi My wife has a stock 05 Harley 883 sportster with a carb.I noticed a couple drips coming off the stock petcock .Do they make a rebuid kit for these ? Or is it better to replace it with a new after...

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

Jun 19, 2011 | 2005 Harley Davidson XL 883L Sportster

1 Answer

Changed the ignition on 1996 sportster xl1200c now it dies out when i start of in first and in second like its not getting any gas

Well, pull the fuel line loose from the carb, put it in a catch can, and spin the engine. The '96 and later Harley's have a vacuum operated petcock if it is still stock. It gets vacuum from the intake maniold or backside of the carb through a small vacuum line. The hose plugs onto the backside of the petcock. If you're not getting any vacuum or the diaphgram in the petcock is damaged, you won't get any fuel to the carb.

Also, try loosening your fuel cap. Don't take it completely off just good and loose. If the fuel tank vent in the cap is plugged, a vacuum will build up in the fuel tank quickly and stop the flow of fuel.

Are you sure you have your ignition system timed and wired correctly?


Mar 27, 2011 | 2000 Harley Davidson XL 1200 S Sportster...

1 Answer

Need to adjust the idle on one cylinder on harley

Ok, first off, this ain't no Yamaha you're messing with. It's a completely different motorcycle in most every way. Not saying it's better or worse than the *** bike but it's different.

It has two cables, this is correct, but only one carb. One cable is the throttle cable and the other is the idle cable. The idle cable pulls the carb shut in the event the throttle plate spring breaks on the carb. It's a safety thing and it was the same way on your Yamaha.

Now, if the front cylinder is not running at idle, I would suspect a vacuum leak somewhere. There are several places where you could have a vacuum leak. Of course, the intake manifold seals could be leaking, the intake carburetor seal could be leaking, or the VOES/ petcock line could be causing a problem. Unless you have taken your air cleaner off for some reason, I'm going to assume that the problem is in the petcock.

Your bike has one of the vacuum operated petcocks in the tank unless it's been changed already. Vacuum from the engine opens the petcock allowing fuel to the carb when the engine is running but when the engine stops, the vacuum disappears and the petcock closes. Supposedly. This is the worst piece of junk Harley ever put on their motorcycles. They do two things, they quit working and won't let fuel into the tank or they cause a small vacuum leak that will cause the bike not to idle properly. I suspect you have the latter case.

Drain your fuel tank by loosening the petcock and allowing the gas to run out around it. Catch the fuel with a large funnel and an empty fuel can large enough to hold the fuel in your tank. Once empty, disconnect the two hoses and remove the petcock. On the backside of the petcock, there is a square plate. Remvove the four small screws and take the plate off. There will be a diaphragm, a spring, and needle under the plate. Remove the plate carefully so you can see how it goes back together. Hold the diphragm up to the light and gently stretch it while looking for holes. If you find a hole, you'll have to either buy a new diaphragm and repair your petcock or , better yet, replace the entire petcock with a manually operated one. A Pingle petcock is a very high quality valve and you'll like it but it is pricey. If you buy an OEM petcock, get one for a 1995 or earlier bike. You will no longer need the vacuum line and you can plug it with a small bolt or something to stop the vacuum leak.

This vacuum line comes off a nipple at the backside of the carb and it feeds vacuum to two things. It's a 3/16" hose that goes up to the VOES switch mounted on the frame under the tank. From there it "Y's" off to the smaller hose that goes to the backside of your petcock. Take your fuel tank off and inspect this hose. Look for cracks. If you go with the manual petcock, eliminate the small portion of the hose by replacing the hose that runs to the VOES with the single hose instead of the "Y'd" hose.

As for the idle speed of you engine, it should be set at about a thousand RPM. Look at the top of the carb. There is a screw near the top on the right side of the carb. That is the throttle stop screw. It controls the idle speed of the engine. Turn the screw clockwise to increase the idle speed.

Ok, try what I've written here. If it doesn't work, get back with me.

Good Luck.

Jul 20, 2010 | 1993 Harley Davidson XLH Sportster 883

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