2003 Sportster 883

It coughs from time to time at lower RPM and usually in the colder weather - under 70s. My research has lead me to believe that it's the carburetor. I have no clue if it was ever serviced, but I don't know that the air mixture screw is still plugged - inaccessible unless you drill out the plug, so it's time for a clean up

First thing first, I'm ordering the carb to manifold seal and I wanted to make sure it's the correct one: Orange Cycle Parts Carburetor to Manifold Seal for Harley Sportster XL, Tour Glide FLT, FXR, Softail, Dyna 1989-2017 Repl. # 27002-89 https://a.co/d/98YMxxb

I'd appreciate if someone can confirm this for me.

 

As for fitment advice, I would speak to the retailer. You're also overdue for new intake seals as well...They can and do cause "coughing"...may as well change them while you are in there...

 

You should replace all three intake manifold seals. Especially the two that seal the manifold to the heads. A good carb rebuild will put a smile back on your face. It's a very simple carburetor, so just take your time and enjoy the learning experience. We're here to help if you need it, good luck.

I'd just order a carb kit that comes with all you need. Take note of what size jets you are running. A 45 pilot is recommended if you have a 42, and probably a 170 mainjet would work well in your 883 if you've put on any aftermarket mufflers and aircleaner. A muffler/exhaust change usually requires some tuning, just doing an airfilter swap not always needed. Take a look at your plugs before you begin for reference.

John

 

^^^^^^^ this. First thing I did when I bought my 2003 was buy the CV performance kit with the ez mixture screw. My bike did not run well at all when I bought it. Rebuilt the carb with that kit and I've had a total of zero problems with the carb in the 5 years I've had the bike.

 

Yep, here you go:

https://cv-performance.com/

And, they will ship to Illinois! I had to trans ship to my sister in MO in order to get parts to me in Xouthern Kalifornia. They have a comprehensive product line.

Myself as well, have not touched the carb in almost 4 years since I did my 1250 motor upgrade.

John

 

Plugs, SE air filter, aftermarket pipes?

This is how I got it. A guy at the dealer said the air filter was aftermarket, but I think it's stock. I do think the exhaust pipes are aftermarket tho - this girl is loud

Spark plugs look fine tho probably old (?)

 

I also took a short video hoping that she would cough, and she didn't except one hiccup:


The whole video is over 10 minutes and youtube lowered the quality of it and I don't expect people to watch the whole thing, but it would be helpful to hear your thoughts. Here are some interesting points:

3:30 you can hear it idle, and me blipping the throttle - I think it's running lean, isn't it?

3:55 - the hiccup - you can barely hear it

8:50 - sped up to about 60 mph towards the end, can't complain about how it accelerates

 

What is the A/C filter element?

 

Plugs look good, a bit on the lean side IMHO. When you see what jets you're using now, that will help go forward, and your idle mix screw setting (turns out). Changing manifold seals should eliminate any age related vacuum leaks.

John

 

Thank John. I really don't want to have any downtime in the middle of the riding season. Can we say I need certain jets so I can order them before I take the carb apart?

I agree that it runs lean. If you had a chance to look at the video you can probably tell.
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