Question about 2005 Harley Davidson XL 1200 C Sportster Custom

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2005 Harley Sportster 1200 Custom stalls at highway speeds

I recently bought a 2005 Sportster Custom which has run perfectly for the first 1000 miles that I have ridden it. I did have to re-flare the nipple coming out of the bottom of the diaphragm operated fuel petcock due to a small fuel leak; but the bike has run perfect until this morning. I smelled fuel, and noticed fuel dripping out of the overflow line on the carb. I shut the petcock and cleaned up the fuel, and then reopened the petcock with no fuel coming out of the overflow (I figured I had a stuck float or some trash in the seat which cleared when I shut the fuel off and turned it back on). The bike ran fine for my morning commute (approx 20 miles). While I was driving home this afternoon, I was on the highway doing about 75 miles an hour and the engine started sputtering, and eventually shut down. I pulled over and was able to restart with absolutely no problem (also checked the gas...almost full tank). Bike rode fine for about four or five miles and sputtered/died again, again I pulled over, put the petcock in reserve and restarted with no problem. Was able to drive home the remaining 2 or 3 miles with no problem. I checked the air filter and the fuel line and don't see any other issues. Any ideas?

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The diaphragm petcock operates by vacuum.
Sometimes, the vacuum line comes unhooked, cracked or broken.

Check the vacuum line.

Also, the diaphragm petcock sometimes dies, and needs replacing.

The reserve DOESN'T operate by vacuum.

Posted on Feb 12, 2014

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  • Contributor
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Clean the carb. With the fuel coming out the over flow that means that the needle and seat aren't being able to do their job. The reason it's sputtering is its running out of fuel. That's why when you pull over it starts right up.. double check the vacuum line to the petcock. But i believe the main culprit is the carb itself.

Posted on Feb 16, 2015

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Posted on Jan 02, 2017

nedkelly900
  • 345 Answers

SOURCE: FUEL ISSUES WITH CARB..

the only thing i can suggest, is a sticky needle and seat, if fuel is coming out the over flow, then the float is not shutting off the fuel running into the carb, it has to go some where, so it comes out the overflow. Pressure in the tank wont have any affect at all with your problem. I would take apart the carby again, and check and clean the needle and seat.
Hope this helps

Posted on Jun 13, 2010

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