Question about 2002 Harley Davidson XL Sportster 883

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Had a fuel leak at shutoff now fuel running oout overflow tube

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You had fuel leak at the petcock and now you've got fuel running out of the carb overflow? Sounds like two separate problems. The fuel leak at the petcock is probably caused by diaphragm in the petcock. In 1996, Harley went to a vacuum operated petcock and they give lots of problems. Usually it leaks because of a hole in the diaphragm. You must take the square plate off the back and take the parts out. Watch carefully how the parts come out. There's a spring, a needle and the diaphragm. Hold the diaphragm up to the light and gently stretch it. If there is a hole in it, replace it.

As for the fuel running out the overflow, you might have trash in the needle and seat. You'll have to take the float bowl off the carb and disconnect the fuel line. Then, carefully slide the pin out that holds the float in the carb. Remove the float and he needle at the same time. Use compressed air and blow any trash out by blowing into the fuel inlet. Gently wipe the end of the needle and reinstall it. It is easier to do this job with the carb off the engine as you can turn the carb upside down to do the work making getting the needle back in much easier. Especially if you've never done this before. It can get tricky.

Good luck
Steve

Posted on May 22, 2011

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