Question about Harley Davidson XL 1200 S Sportster Sport Motorcycles

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After cleaning the carb on my 1991 Harley Sportster 1200 XL, gas is leaking out of the overflow. I removed the floatbowl and checked the operation of the float which works properly but everytime i reinstall the floatbowl it leaks

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  • Anonymous Mar 29, 2014

    gas overflow from float tube

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Remove fuel line from carb remove float bowl remove float and needle blow air from needle there is trash in nedle and seat put back together MOPAR KENNY

Posted on May 22, 2011

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1 Answer

Sportster 1200 problems


Either the needle and seat are not fully seating and sealing OR the float level is not set right. Where is the carb leaking from, internally or out the overflow?? That is the nest question.

May 19, 2014 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

2002 sportster wont spray gas to the carb sometimes


Hi Anonymous, if you have a carburator the usual suspects are:
1. Damaged or restricted fuel tank venting system (gas cap).
2. Inlet system air leak.
3. Vacuum piston malfunction.
4. Accelerator pump leaking or no output.
5. Plugged bowl vent.
6. Fuel level (float chamber) too low.
7. Restriccted fuel supply passages.
8. Plugged jets or passages.
9. Worn or damaged needle or needle jet.
10. Enrichner valve not seated or leaking.
Good luck

Apr 02, 2012 | 2002 Harley Davidson XL 1200 C Sportster...

1 Answer

2000 Harley Sportster 1200 XL carb leaking gas and overflow tube leaking gas when running. Help!


Hi Madmaxlunkma, and the usual suspects are:
1. Damaged or restricted fuel tank venting system.
2. Loose float bowl screws.
3. Damaged float bowl o-ring.
4. Improper fuel level in float bowl.
5. Worn or dirty inlet valve or seat.
6. Damaged or leaky float assembly.
7. Particle contamination in inlet fitting cavity.
8. Ethanol sludge, dirt, rust in bottom of fuel tank
Good luck

Dec 31, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

Carburator leaks gas was from over flow on 1989 1200 sportster


float needle valve worn,floats can be fuel soaked causing the float needle valve not to close,may need float height adjustment,either case a carb clean rebuild will help.

Feb 10, 2011 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

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

Jun 13, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

2 Answers

2000 XL 1200 S Sportster Sport: 2003 Harley 883 Sportster Hugger sat for a year. D...


Remove the carb soak in carb cleaner, **** out small bleed holes with a wire from a wire brush etc. One of the passageways is still clogged, or the float is sticking.

May 17, 2010 | 2000 Harley Davidson XL 1200 S Sportster...

1 Answer

2003 Harley Davidson XL 1200 C Sportster It starts and runs perfect when cold.When it warms up to 150 degrees at wide open acts like it is running out fuel,At 180 does it at half throttle and above,At 190...


That's a strange one. The only things I can think of suggesting are:
  • Clogged gas cap vent. The next time is starts running poorly, remove the gas cap briefly and see if things improve. If so, then the cap is not venting as it should.
  • Moisture trapped in float bowl. Drain the contents on the carburetor float bowl into a clean container and check for dirt, rust, water, or anything else that doesn't belong there.
  • Dirty fuel filter. If there is one, replace it.
  • Air leak between carb and engine. Check tightness of clamps and manifolds for cracking. WD-40 sprayed around those areas with the engine idling will help detect any leaks.
That's all I can think of. Please let me know if any of my suggestions fixed it.

Dec 09, 2009 | 2003 Harley Davidson XL 1200 C Sportster...

1 Answer

Gas is streaming out of my overflow line.


I don't work on Harleys but I know it is a stuck float when the gas flows. The following is what I tell the Japanese bike owners.

This is a carb float being stuck open. Turn off the gas and drain the offending carb(s). Next, turn the gas back on and sharply tap the float bowl with the plastic handle of a screwdriver as the fuel bowl refills. The goal here is to vibrate the float to free it up. If doing this process a couple of times doesn’t free the float I would remove the offending carb(s) and clean with a spray carb cleaner. By the way, the float itself could be bad > filled with gas instead of air. Clean the air filter then re-mount carb(s).

Please rate this solution. Thanks!

Apr 18, 2009 | 2000 Harley Davidson XL 1200 C Sportster...

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