Harley Davidson Sportster (1959 to 1969). Service manual - page 8
Turn the entire body upside down, drop in the idle
tube (28), small end first, jiggle the body, and the tube will locate
itself in the body hole. Do not bend, twist or damage the idle tube in
any way. Press on plug end of tube until tube is seated and the bottom
of the plug extends approximately 1/32 in. out of nozzle passage. When
installing bowl nut (26) and gasket (27), spring tension will hold the
idle tube firmly in place.
Assemble support bracket (25), nut and lock washer (24).
CARBURETOR BOWL
Assemble bowl to carburetor main body with four attaching screws (16)
and gasket (18).
THROTTLE BODY
Install throttle shaft (13), counterbored screw head notches facing
towards carburetor main body. Position throttle disc (8) in shaft,
milled side up and facing carburetor body. Insert and tighten shaft
screws (7). Work disc several times. If there is any binding, loosen
screws and reposition disc.
Install only replacement throttle disc containing same identification
number on face. With disc correctly installed and closed, the number
will be on top half of disc facing carburetor main body.
Install screw (14) and spring (15). Assemble throttle lever to shaft
(10) with spring (11) and washer (12) allowing slight end play in the
shaft when lever assembly is clamped tight. Position throttle disc and
throttle lever in wide open position before tightening screw (9).
Install low-speed needle valve (4), washer (5) and spring (6). Be
careful not to jam the low-speed needle point into its seat. Install
idle hole body plug (3). Install idle passage tube (36) in carburetor
body, chamfered end out. Install a new throttle body gasket (2),
position throttle body in place and insert screws and lock washers (1).
The Model DC carburetor is attached to the manifold flange with certain
thickness gasket and certain length cap screws. If for any reason the
overall gasket thickness is reduced and no change is made in the cap
screw length, the cap screw may bottom on the head of the lower throttle
body screw (1). If it does bottom, a broken throttle body will result.
After assembly, adjust carburetor as described in "Adjusting
Carburetor."
All pertinent calibration and setting figures not given in prior
information appear in following chart.
