IH: Carburetor, Intake Manifold & Exhaust - Sub-01F


Rebuilding the Tillotson Carb

Parts List

Click on the diagram below to enlarge.




The list below is compilation parts list gathered from Tillotson documentation for carbs factory mounted to Sportsters.
( Click Here ) to download a PDF version of this chart. Use the reference numbers below with the diagram above.

Ref
No.
HD
Part#
Description Tillotson Part No. per Carb
HD1A HD1B HD1C HD1D HD5A
127760-66* Accelerator Pump Assembly 013785 013785 013785 013785 —-
227759-66Accelerator Pump Lever 012761 012761 012761 012761 012761
32540* Accelerator Pump Lever Screw 06393 06393 06393 06393 06393
47005* Body Channel Cup Plug (2) 06396 06396 06396 06396 06396
5* Body Channel Cup Plug (2) 010588 010588 010588 010588 010588
9711* Body Channel Welch Plug (2) 04326 04326 04326 04326 04326
10713* Body Channel Welch Plug 013737 013737 013737 —- 013737
11712* Body Channel Welch
Plug (Choke)
03489 03489 03489 03489 —-
1227406-26Choke Friction Ball 04784 04784 04784 04784 —-
1327671-66Choke Friction Spring 08805 08805 08805 08805 —-
1627668-66Choke Relief Valve 013742 013742 013742 013742 —-
1727669-66* Choke Relief Valve Spring 013775 013775 013775 013775 —-
1927718-66Choke Shaft & Lever 013777 —- —- —- —-
27718-67 —- 014296 014296 014296
2127661-66Choke Shaft Seal 09484 09484 09484 09484 —-
2227673-66Choke Shutter 013741 013741 013741 013741 —-
2327720-61* Choke Shutter Screw (2) 08942 08942 08942 08942 —-
2427716-67Choke Wire Connection —- 014294 014294 014294 —-
2527716-55Choke Wire Retainer Clip —- 010392 010392 010392 —-
2627716-61Choke Wire Connection Washer —- 012174 012174 012174 —-
27993WChoke Wire Ret. Screw —- 012305 012305 012305 —-
2827806-66Diaphragm Gasket 013731 013731 013731 013731 —-
27806-66R —- —- —- —- 014120
2927816-66* Diaphragm 013790 013790 013790 013790 —-
27816-66R —- —- —- —- 014248
3027804-66ADiaphragm Cover 014871 014871 014871 014871
27804-66R —- —- —- —- 014117
3127812-66Diaphragm Cover Plug Screw 013771 013771 013771 013771 —-
3227814-66Diaphragm Cover
Retainer Screw (6)
010278 010278 010278 010278
27812-66R 014142
3327407-66Economiser Check Ball 05322 05322 05322 —- 05322
4327352-66Intermediate Mixture Screw 013772 013772 013772 013772 013772
43A27688-66Idle Mixture Screw 013787 013787 013787 013787 013787
4427689-61* Intermediate Mixture Screw Spring 011103 011103 011103 011103 011103
44A27689-61* Idle Mixture Screw Spring 011103 011103 011103 011103 011103
4527354-66Intermediate Mixture Screw Washer 03114 03114 03114 03114 03114
4627353-66Intermediate Mixture Screw Packing 010511 010511 010511 010511 010511
4727717-66* Idle Speed Screw 012177 012177 012177 012177 012177
4827747-66Idle Speed Screw Cup 010050 010050 010050 010050 010050
4927691-59* Idle Speed Screw Spring 0788 0788 0788 0788 0788
5427644-66Idle Speed Screw Washer 04920 04920 04920 04920 04920
5527740-66* Inlet Control Lever 014020 014020 014020 014020 014020
5627613-66* Inlet Control Lever
Fulcrum Pin
013406 013406 —- —- —-
27595-66 —- —- 015397 015397 015397
5727596-66* Inlet Control Lever
Fulcrum Pin Screw
013269 013269 013269 013269 013269
5827588-66Inlet Needle, Seat & Gasket 014224 —- —- —- 014224
27597-67 —- 014853 014853 014853
59A27746-66* Inlet Screen (2) 010301 010301 010301 010301 010301
6127598-66Inlet Seat Gasket 013744 013744 013744 013744 013744
6227599-66* Inlet Tension Spring 013434 013434 013434 013434 013434
6727745-66RHigh Speed Mixture Screw —- —- —- —- 013855
6827834-71High Speed Mixture Screw Gland —- —- —- —- 013853
6927698-61High Speed Mixture
Screw Gland Gasket
—- —- —- —- 0676
7027353-66High Speed Mixture
Screw Gland Packing
—- —- —- —- 010511
7127689-61* High Speed Mixture Screw Spring —- —- —- —- 011103
7227354-66High Speed Mixture Screw Washer —- —- —- —- 03114
7427615-66Main Fuel Jet (.057) 011394 011394 011394 011394 —-
27619-66RMain Fuel Jet (.089) —- —- —- —- 014313
74A27640-66Main Fuel Jet Gasket 06076 06076 06076 06076 —-
27830-71 —- —- —- —- 013683
7527704-61Main Fuel Jet Plug Screw 01102 01102 01102 01102 —-
7627658-66Nozzle Check Valve 013789 013789 013789 013789 013789
7827407-66Pump Outlet Check Ball —- —- 05322 05322 —-
79Pump Outlet Check Ball Retainer —- —- 012153 012153 —-
8727708-66Throttle Shaft & Lever 013782 —- —- —- —-
27708-67 —- 014297 014297 014297 014297
9lA27706-66* Throttle Shaft Compression Spring 013738 013738 013738 013738 013738
9227707-66Throttle Shaft Seal (2) 013740 013740 013740 013740 013740
9427712-66* Throttle Shaft Seal Washer (2) 013746 013746 013746 013746 013746
96013745Throttle Shutter 013745 013745 013745 013745 013745
972545W* Throttle Shutter Screw (2) 08942 08942 08942 08942 08942
10027715-67Throttle Wire Connection —- 014225 014225 014225 014225
101515Throttle Wire
Connection Retainer Clip
—- 0379 0379 0379 0379
1026189WThrottle Wire Connection Washer —- 05413 05413 05413 05413
103993W* Throttle Wire Retainer Screw 058 058 058 058 058
* Gasket Set GS-2HD GS-2HD GS-2HD GS-2HD GS-2HD
Repair Parts Kit RK-3HD RK-3HD RK-3HD RK-3HD RK-3HD

(*) Indicates contents of Repair Parts Kit

Cleaning

  • The general appearance of the inside of the carb is not necessarily a good indication of its condition.
    It can look spotless and have clogged jets, or look cruddy and have clear jets.
  • It's good to clean each individual part rather than soak or boil the whole carb in carb cleaner.
    But either way is good. Do not allow any solvents to contact any rubber parts (tip of needle, O-ring seal for bowl).
  • Make sure to take everything apart, jets, needle, accel pump, all rubber components especially.
  • Examine all parts for excessive wear, damage, distortion, etc.
  • Cleaning solutions/sprays vary based upon your location, needs, budget, preferences and quality.
    Dismantle the carb down to the body before soaking. You will be surprised at all the dirt in the bottom of the soaking container.
    Here are some helpful ideas:
    • An overnight soak in a solution of Pinesol and water followed up with a good brush down with a toothbrush then rinse and air dry. 1)
      See also Soaking parts in the REF section of the Sportsterpedia.
    • A 20 minute to up to a few days soak in a gallon of Gunk (or other) Carburetor Cleaner that has a basket inside for small parts and lowers in the can with a handle, rinse, air dry, use.
    • Soak it in mineral spirits for a few days. 2)
    • You can use acrylic paint thinners for cleaning up carb parts. It melts the fuel varnish right off. 3)
    • An aerosol spray carb cleaner will also work but may not loosen all of the build up in the jets or orifices in the carb body if they're not directly sprayed through.
  • Blow out all holes, jets and orifices thoroughly with compressed air after cleaning.

A gallon of carburetor cleaner is very useful in cleaning out varnish from the channels and metering chamber.
It is especially useful for soaking stuck gaskets between parts and loosen the joint between them for dis-assembly.
Depending on how old or how 'stuck' the parts are, soaking for a couple hours may help to separate the old gasket in between.
Make sure to remove any rubber or plastic parts before soaking. Also check the label for safety precautions.
Parts that have been sitting for years may have to be soaked for about 24 hours or even days.

Carburetor Cleaner 4)

Note:
The use of wire to 'rod' out jets and orifices is discouraged in the FSM.
However, a hard wire such as a welding tip cleaner, has been known to open up stubborn areas at times.
Always use a wire smaller than the orifice cleaned so you don't widen the holes.
Doing so could create burrs or change the hole sizes.

Carb Stand:

  • You can put the carb in a vice to remove the screws, and for much of the following work.
    Wrap in a shop towel; close the vice gently taking extra care with the choke and throttle linkages.
    The vice is a needed extra pair of hands.
  • It can be very confusing trying to decide which way to bend the tang if it is not correct.
    If the fuel level is low,Is the float high or low?, Do you need to bend the tang up or down? etc.
    On the bench the carb is usually upside down, adding to the confusion. You should sort all this out before making an adjustments.

However, this setup works better than putting the carb directly into the vice.
The carb is set upright as 'in use' making adjustments more straight forward.
5) 6)

Related Service Bulletins

There are 5 known technical service bulletins related to Tillotson carbs.
Click Here to go to the Service Bulletin page in the Sportsterpedia.
You can scroll down to the following bulletins and click the “Y” next to each bulletin to download it.

  • TSB# 518 dated 9-10-1965 (Includes operation, adjustments, troubleshooting and servicing.)
  • TSB# 547 dated 10-24-1966 (Models produced after August 10, 1966 have a new carburetor inlet valve lever, needle and seat assembly.)
  • TSB# 564 dated 1-15-1968 (Instructions included for Adjusting, Diagnosing, Disassembly, Cleaning and Assembling).
  • TSB# 571 dated 5-21-1968 (Tillotson carbs changed to incorporate a ball check valve in accelerating pump passage of plastic cover.)
  • TSB# 605 dated 11-28-1969 (Addresses shipments of defective needles with incorrectly formed blunt ends instead of tapered.)

Welch Plug or Expansion Plug

  • Inspection:
    • A close inspection around the walls of a welch plug can reveal possible leaks.
  • Removal: 7)
    • Whenever a welsh plug is removed, a new one should be installed in it's place, especially since a large part of the time, removal of one means destroying or deforming it.8)
    • Drill an 1/8“ hole thru it (just deep enough to break thru to the other side) off center and pry it out with a small punch. Be careful not to drill too deep which could destroy the nozzle assembly or casting. While prying it out, be careful not to damage the casting counter-bore edges around the plug.
    • You can also drill a small hole in it and use a small tap just big enough to start in the hole. 9)
      Thread the tap in the hole.
      When it gets to the bottom of the passage, it will force the valve out with out damaging the bottom of carb passage.
      Make sure to clean all the chips out to keep from plugging up passages later.
  • Installation: 10)11).
    • The plug should be seated with a flat end punch that is slightly smaller than the diameter of the plug. The plug should be flat and not concaved to assure a tight fit. If leakage is suspected due to a rough or damaged welch plug seat in the casting, apply a small amount of epoxy or suitable sealant to the edges after installing it.

Links to Welch plug sites:

Diaphragm

The diaphragm for HD1 carbs is HD part# (27816-66).

12)

Links,Parts and Services for Tillotson Carbs

Original P/N for a Sporty Tillotson repair parts kit 27147-66 13)
Original P/N for a Big Twin Tillotson repai parts kit 27137-66

Tillotson Carburetor repair/ refresh kit14)

Full Tillotson / HD Carb Part# Cross Reference Chart

Cross reference list between HD part#s and Tillotson part#s provided by sungod of the XLForum.

HD Part#Tillotson Part#Description HD Part#Tillotson Part#Description
71104326Welch Plug27705-6108850Nozzle
71203489Welch Plug27705-66014049Spring
713013737Welch Plug27705-66A015253Spring
1065W08315Screw & Lockwasher27706-57010519Spring
2545W08942Screw & Lockwasher27706-63012823
2546W09066Screw27706-66013738Spring
27119-74HD-14lACarburetor27707-5707824Seal
27123-70RHD-43ACarburetor27707-66013740Seal
27132-66RRK-723Repair Kit27708-55010444Shaft
27133-66GS-1HLGasket Kit27708-57010844Shaft
27134-66RK-8HLRepair Kit27708-66013782Shaft & Lever
27135-63RK-572Repair Kit27708-67014297Shaft & Lever
27135-66RK-3HDRepair Kit27709-5508597Clip
27135-66RK-659Repair Kit27710-55010446Lever & Swivel
27135-66RK-660Repair Kit27710-59011691Lever & Wire Connection
27137-66RK-764Repair Kit27711-55010445Lever
27138-63GS-168Gasket Set27712-5503804Washer
27138-66GS-187Gasket Set27712-66013746Washer
27138-66RGS-204Gasket Set27713-5509067Lever
27138-71GS-223Gasket Set27713-5908490Throttle Stop Lever
27139-66RRK-771Repair Kit27714-5508646Shutter
27140-71RK-988Repair Kit27714-61012146Shutter
27143-61MD-119ACarburetor27714-63012283Shutter
27144-59MT-76ACarburetor27714-66013745Shutter
27144-63MD-l19BCarburetor27715-55010393Connection
27145-55MT-43ACarburetor27715-59011686Choke & Wire Conn.
27145-55AMT-43BCarburetor27715-61012328Connection
27145-60MT-82ACarburetor27715-66013534Shutter
27150-71HD-77ACarburetor27715-67014225Connection
27150-7lAHD-77BCarburetor27716-55010392Washer
27152-66HD-2DCarburetor27716-61012174Washer
27152-66AHD-1BCarburetor27716-67014294Connection
27152-66BHD-2DCarburetor27717-5905095Screw
27154-66RHD-5ACarburetor27717-66012177Screw
27155-66HD-1CCarburetor27718-61012334Shaft & Lever
27155-66AHD-1BCarburetor27718-63012806Shaft & Lever
27155-66CHD-IDCarburetor27718-66013777Shaft & Lever
27158-63HL-139ACarburetor27718-67014296Shaft & Lever
27158-63HL-139BCarburetor27719-6002672Bushing
27158-63AHL-212ACarburetor27720-6108942Screw & Lockwasher
27158-67HL-23lACarburetor27721-55GS-106Gasket Set
27249012741Washer27721-61GS-116Gasket Set
27273-63012825Lever27722-55RK-164Repair Kit
27274-67A015594Lever27722-59RK-397Repair Kit
27274-67014266Lever27722-60RK-467Repair Kit
27276-63012826Shaft & Lever27722-61RK-472Repair Kit
27276-66014050Shaft27725-6109644Shutter
27277-66R014297Shaft & Lever27726-6109678Clip
27295-66RRK-697Repair Kit27727-6109780Bushing
27317-63012284Jet (.043)27728-61010079Lever
27347-69012392Spring27729-61012111Clip
27352-66013772Mix. Screw27730-61013618Spring
27353-66010511Ring27730-63012821Shaft & Lever
27354-6603114Washer27730-66014048Shaft & Lever
27407-6605322Ball27730-67014268Choke Shaft Assem.
27411-67R08304Gasket27731-61011072Seal
27413-63010165Gasket27731-65013507Spring
27415-6107903Gasket27732-6101974Screw
27593-66012956Nut27732-63010571Screw
27595-66015397Fulcrum Pin27733-610992Lockwasher
27596-66013269Screw27734-62010911Screen
27597-66013774Needle & Seat27735-6106062Screw & Lockwasher
27597-67014853Needle & Seat27736-6507847Washer
27598-66013744Gasket27740-61012321Mix. Screw
27599-66013434Spring27740-63010513Control Lever
27601-63010529Gasket27740-66014020Control Lever
27613-66013406Pinion Pin27740-70R013589Inlet Lever
27615-66011394Jet (.057)27742-61012326Spring
27616-66011396Jet (.061)27743-61012327Stop Screw
27617-66011765Jet (.053)27744-61012332Screw
27618-66011722Jet (.055)27745-66R013855Mix. Screw
27619-66011395Jet (.059)27746-66010301Screen
27619-66R014313Jet (.089)27747-66010050Cup
27620-66011385Jet (.063)27759-66012761Lever
27622-66011764Jet (.051)27760-63010525Pump Body
27624-66011763Jet (.049)27760-66013785Pump Assembly
27640-6606076Gasket27760-71014992Shaft and Lever
27643-71014645Pump Body27760-71A015959Shaft and Lever
27644-6604920Washer27761-63012930Gasket
27658-66013789Check Valve27775-7408942Screw & Lockwasher
27661-6609484Seal27804-63014336Diaphragm Cover
27667-71015937Lever Assembly27804-66013772Pump Body
27668-66013742Relief Valve27804-66A014871Pump Body
27669-66013775Spring27804-66R014117Diaphragm Cover
27670-5505454Friction Pin27805-63010527Strainer Cover
27671-6608805Spring27806-63012473Gasket
27672-5509158Shaft & Lever27806-66013731Gasket
27672-59011692Shaft & Lever27806-66R014120Gasket
27672-61012330Shaft & Lever27807-63010098Screw & Lockwasher
27672-63012811Shaft & Lever27808-63010530Strainer Screen
27673-5505088Shutter27809-63012698Diaphragm
27673-66013741Shutter27809-63A014229Pump Diaphragm
27674-63012818Shutter 014230Pump Diaphragm
27674-63A09558Shutter27810-63011428Washer
27674-66014816Shutter27811-63011401Packing
27675-5508880Gasket27812-6302232Plug Screw
27678-6103311Plug Screw27812-66013771Screw
27679-6107896Plug Screw27812-66R014142Screw
27680-55012144Float27813-63011503Spring
27680-61011294Float27814-66010278Screw & Lockwasher
27680-63012813Float27815-63012084Check Valve
27681-55011564Pin27816-63012475Diaphragm
27682-55010471Cover27816-66R014248Diaphragm
27683-5508658Gasket27816-66013790Diaphragm
27684-61012616Fuel Bowl27817-71014248Diaphragm
27685-61011859Pinion Screw27818-66013094Gasket
27688-5508765Mix. Screw27821-63012370Jet (.041)
27688-61012318Mix. Screw27819-63014540Jet (.037)
27688-63011825Mix. Screw27820-63013266Jet (.039)
27688-66013787Mix. Screw27822-63012284Jet (.043)
27688-71015698Mix. Screw27823-66R011482Jet (.081)
27689-5508793Spring27824-71014348Spring
27689-61011103Spring27825-71014118Clip
27690-6106569Gasket27826-71014997Nut
27691-5509068Spring27827-71014998Screw
27691-590788Spring27828-71014995Clamp
27692-5508875Idle Tube27829-71014999Bracket
27692-60011127Idle Tube27830-71013683Gasket
27692-61012320Idle Tube27831-71011516Screen
27693-5509120Needle & Seat27832-71014578Check Valve
27693-59011688Needle & Seat27833-71014993Jet (.089)
27693-61012325Needle & Seat27833-74016995Jet (.0635)
27693-63012339Needle & Seat27834-71013853Gland
27693-66014053Needle & Seat27835-71014247Mixture Screw
27694-5502510Gasket27836-71010079Lever
27695-66R013854Mix. Screw27837-71014647Diaphragm
27696-63010581Screw27838-71014646Gasket
27696-66013269Screw27839-71015219Spring
27697-6109112Packing27840-71015218Screen
27697-66R013853Gland27841-71015596Needle & Seat
27698-610676Gasket27842-71013406Pinion Pin
27699-55010347Mix. Screw27843-71014239Mixture Screw
27699-5907972Main Adj. Screw27844-71014937Strainer Cover
27700-550705Packing27845-71014644Diaphragm
27700-610702Gland27846-71014643Gasket
27700-63012822Screw27847-71015455Elbow Connector
27701-5507282Packing Nut27848-71015941Diaphragm Cover
27701-610703Packing Nut27849-71014120Gasket
27702-5509159Nozzle27850-71015010Shutter
27702-6009070Nozzle27851-71015052Shaft
27703-5506076Gasket27852-71014988Screw & Lockwasher
27704-6101102Plug Screw27853-71015384Screw
27704-660675Plug Screw27854-71014687Screw & Lockwasher


4)
photo by Hippysmack
6) , 14)
Pic courtesy of The Doctor71 of the XLFORUM
7) , 10)
HD Service Bulletin #518 dated September 10, 1965 pg OC-189
8) , 11)
1959-1969 HD Sportster FSM
12)
photo courtesy of C & M Sales, Link to Ebay Store
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