Question about 2003 Harley Davidson XL 1200 C Sportster Custom

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Poping in crub - 2003 Harley Davidson XL 1200 C Sportster Custom

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I think you're talking about "popping in carb". This is because your carb is jetted too lean from the factory. They have to do this to meet EPA regulations. You need to change the slow speed jet in your carb from a #42 jet to a #45 jet. Making this change will usually require that you drill out the "anti-tamper" plug that covers the idle mixture adjustment screw so that the idle mixture can be adjusted for the new jet.

Also, you need to remove the slide from the carb and remove the needle. With the needle out, slide a 3mm flat washer on the needle from the "long" side. The small flat washer is approximately 0.020 to 0.023" thick. This will raise the needle by this much slightly enriching the mid-range mixture. You can use a little grease to hold the washer on the needle while you reinstall it.

This is a relatively complicated job in that it requires the removal of the carb from the engine and disassembly of the carburetor. It is also a job that I do not recommend for the amateur mechanic.

Good Luck

Posted on Nov 10, 2010


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