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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #1  
Old 10th January 2011
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Default jetting help for XL1200S Sport

I'm living in Tokyo Japan and am in the process of taxing my 2001 XL1200S Sport model. Parts here are super expensive and so I am having them purchased in USA and sent to me here.

I have a really nice Sundance Orange II high performance muffler (this I purchased here!), and a K&N filter but I'm having trouble figuring out which ThunderJet Kit I need and which Thunderslide Jet Kit I need for this model.

I'm pretty sure the product number for the ThunderJet Kit is: 10070152 - but I'm unsure about the ThunderSlide Jet Kit? The internet has too much confusing onformation and there seem to be so many ThunderSlide kits to choose from. The XL1200S is different from other XL's and so usually requires special parts. I dont wish to make a mistake when purchaseing the thunderslide.

Can anyone guide me to the correct parts for my Sporty Sport?
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  #2  
Old 10th January 2011
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  #3  
Old 10th January 2011
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done
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  #4  
Old 12th January 2011
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You do not NEED a DynoJet kit or DynoJet Thunderslide kit. Just rejet the carb with the right jets and you are good. As far as which kit you'd need to buy if you really wanted one, it is part number 8103 for the DynoJet kit and 8112 for the DynoJet Thunderslide kit. There is nothing special about the 1200S carb compared to the other 1200 cc Sportsters the same year. Again though, just buy a few Keihin CV jets (pilot and main) and tune it.
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  #5  
Old 13th January 2011
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Thanks for the reply and the advice. I am going to replace the CV carb for the FCR. With thanks to the posters here and other Harley forums I now realize the jet kits are not worth the money.
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  #6  
Old 13th January 2011
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Replacing the carb is hardly worth the money either, unless you're doing headwork. I'm no mechanic, but from the help of the knowledgeable guys on here, I got ALOT of extra power from an AC/exhaust setup and properly tuned and sized jets.
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Old 15th January 2011
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Quote:
Originally Posted by Shu View Post
You do not NEED a DynoJet kit or DynoJet Thunderslide kit. Just rejet the carb with the right jets and you are good. As far as which kit you'd need to buy if you really wanted one, it is part number 8103 for the DynoJet kit and 8112 for the DynoJet Thunderslide kit. There is nothing special about the 1200S carb compared to the other 1200 cc Sportsters the same year. Again though, just buy a few Keihin CV jets (pilot and main) and tune it.
Shu, Good advice. Just for clarity's sake, isn't the 1200 S model's carb the same as the other 1200 models of the same year but didn't H-D equip the stock S model's carb with a larger main jet and a different needle than the standard 1200 or am I mistaken? Of course some of that may need changing when tuning for aftermarket intake and exhaust.
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Old 15th January 2011
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Don that is correct. I forget what needle it is, I wanna say the NOKK, but I don't recall for certain at this moment.

Sportster.org in the techies has a good list of the stock jet sizes as well as suggestion for jetting when adding air filter and or pipes...
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  #9  
Old 15th January 2011
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Quote:
Originally Posted by Don Burton View Post
Shu, Good advice. Just for clarity's sake, isn't the 1200 S model's carb the same as the other 1200 models of the same year but didn't H-D equip the stock S model's carb with a larger main jet and a different needle than the standard 1200 or am I mistaken? Of course some of that may need changing when tuning for aftermarket intake and exhaust.
The US Sport did come with a different main jet (27275-96Y) which I think was a 190 main out of the Buell. It also received a needle (27656-98) which was different than the standard (27241-95) needle that the rest received. I don't recall the exact needle codes but here are the part numbers for comparison. Additionally the California 1200 S got a differnet needle yet, it was the 27254-96. California bikes not only received a different main jet but they had different needles. I haven't researched it enough to know the relationship between the main and needle on the Sport or California models, but I would guess that where HD increased the main Jet size they then leaned out the needle some in the cruiseing area and light throttle area even further for emissions reasons. All models domestic received the 42 pilot jet. Oh yeah and the 1200S had a different float chamber assembly as well (27380-98 instead of 27159-92). That, I believe was a slightly larger volume float bowl but have never been able to verify.

FWIW here are the entire carb part numbers by model:
27490-96 - 883's
27495-96 - California 883's
27480-97 - 1200's
27498-96 - California 1200's
27731-98 - 1200 Sports
27732-98 - California 1200 Sports

Those parts were the same from 96, 97 or 98 as indicated through 2003.

Dynojet makes kits specific to the Sport due to this and those are the part numbers I mentioned earlier. I still don't think he needs a DynoJet kit, only a few jets at most.
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  #10  
Old 15th January 2011
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Yes, I had thought that the S model had a difference in the float bowl as well but I didn't know what it was and failed to mention it.
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