Easy Kit Installation Instructions
HSR Carburetor
Easy Kits
Installation Instructions
For
Evo Big Twin Kit: # 42-7
Twin Cam Kit: # 42-18
Revised 01/23/02
EK-1
Easy Kit Installation Instructions
The HSR series carburetors are precise yet durable instruments; however, like any other piece of fine equipment, they
require correct installation and reasonable care to assure optimum performance and long life. Extra time spent during
installation will pay off in both short and long term performance and reliability.
This Mikuni HSR carburetor kit is designed to be a bolt-on application, and as such, is set-up and jetted properly for
most applications. However, since many Harley-Davidson motors are often highly modified, alternate tuning settings may
be required.The Mikuni HSR Tuning Manual helps make jetting alterations and adjustments an easy matter.
NOTE: Carburetor Kits not designated as C.A.R.B. exempt, are not legal for motor vehicles operated on public highways in
the state of California, or in any other states and countries where similar laws apply.
Disassembly
Notes, Cautions and Warnings
Statements in this manual preceded by these words are
very important:
NOTE:
Gives helpful information that can make a job easier.
CAUTION
Indicates a possibility of damage to the vehicle if instructions
are not followed.
WARNING
Indicates a possibility of personal injury or vehicle damage if
instructions are not followed.
1. Disconnect the negative (-) battery terminal.
2. Turn the fuel petcock to the “OFF” position.
3. Elevate the rear of the fuel tank for better access. It is
not necessary to remove the tank to install this kit.
4. Remove the air cleaner assembly, including the backplate.
5. Disconnect the choke cable from its bracket.
6. Disconnect the vacuum and fuel hose from the carburetor.
7. Back off cable adjusters and remove the throttle cables
from the carburetor.
8. Remove the carburetor from the motorcycle.
9. Remove enrichener (choke) cable from the carburetor.
Installation
WARNING
Read these instructions carefully before you begin installation of your HSR kit. All procedures in this manual should
be followed, paying particular attention to the following:
1.
2.
3.
4.
Mikuni HSR series carburetors require the use of a push/pull
throttle assembly to assure closing of the throttle valve.
The throttle cables should be routed freely (without sharp
bends) between the throttle twist grip and the carburetor and
must not be pinched.
Gasoline is extremely flammable and is explosive under certain conditions. Do not install your Mikuni near open flame.
Never look directly into the bore of the carburetor while the
engine is running as injury may result from possible backfire.
1. Choke Cable (Evo & Twin Cam)
A. Remove the Harley choke cable from the stock carb.
B. Remove the spring and plunger from the cable.
C. Remove the spring and plunger from the Mikuni carburetor.
D. Install the Mikuni spring and plunger onto the Harley
choke cable. Change nothing else; be sure to use the
Harley plastic nut, not the Mikuni nut (See Figure1).
E. Install the new assembly into the Mikuni carburetor. Be
careful to only gently tighten the plastic nut.
CAUTION
A moderate level of mechanical skill is required to install this
carburetor kit. After reading these instructions, if you have any
doubts, we recommend that you have a professional install it for
you. If you install the kit yourself, we recommend that you also use
the applicable shop manual for your motorcycle.
Harley Nut
Mikuni Spring
Figure 1
Mikuni Plunger
EK-2
2. Throttle Cables
3. Carburetor Installation
WARNING
Control cables must not pull tight when handlebars are turned to
the left and right fork stops. Also, be sure control cables and wires
are clear of the fork stops at the steering head so that they will not
be pinched when forks are turned against stops.
A.
The HSR carburetor uses the stock throttle cables.
However, new cable routing is required to prevent cable
binding. To re-route the cables you must elevate the
rear of the tank. Cut the stock cable tie from the frame,
located above the front cylinder. Some models may use
sheet metal clips; if so, remove the cables from the clip.
Re-route the cables under the frame (Figure 2).
A. Insert the carburetor into the stock Harley-Davidson
manifold. The carburetor will fit very snugly. Use grease
as a lubricant. Be sure that the choke routing doesn’t
become kinked.
B. Slip the fuel hose onto the carburetor’s fuel nipple and
secure with the enclosed hose clamp.
C. Some Twin Cam installations may require removal of a
small amount of fin material from the cylinders to clear
the float bowl.
NOTE:
1.
2.
If you are not using the V.O.E.S. or vacuum petcock, be sure to
cap the vacuum fitting on the carburetor.
Before installing the carburetor, check the condition of the
carburetor seal; if damaged, it should be replaced to prevent
air leaks. We recommend that you start with a new seal.
4. Stock Backplate (1340 Evo Only)
A. Insert the enclosed large diameter O-ring into the
Mikuni adapter. Attach the adapter to the stock backplate with the provided screws. Do not use the stock
screws; they are too long.
B. Use a small amount of thread lock on each of the
screws (Figure 4).
C. Align the carburetor so that it is centered between the
front and rear cylinders. Secure the backplate to the
engine with the stock bolts.
NOTE:
1.
2.
Before attaching the backplate, check that the carburetor is
inserted fully into the intake manifold. If the carburetor is not
fully seated, air leaks might result.
If you are using the Screamin’ Eagle air cleaner kit, refer to the
instructions from that kit.
Figure 2
B. Connect the throttle cables to the carburetor bell crank
by first installing the closing cable, then the opening
cable (Figure 3).
Figure 3
Figure 4
EK-3
5. Backplate (Twin Cam 88)
A. Insert the enclosed large diameter O-ring into the
Mikuni adapter. Assemble the stock backplate and
adapter using the enclosed gasket and stock gasket .
Use a small amount of thread lock on each of the stock
screws.
B. Insert the enclosed small O-rings into the 1/8” spacers.
The spacers mount between the backplate and heads.
Secure the backplate to the engine using the spacers
with the O-ring facing the engine (Figure 5).
7. Cable Lube
Remove upper throttle housing and inject cable lube in
each cable (Figure 7).
NOTE:
Before attaching the backplate, check that the carburetor is
inserted fully into the intake manifold. If the carburetor is not fully
seated, air leaks might result.
Figure 7
8. Throttle Cables — Adjustment
WARNING
It is important to adjust the cable as described below to
ensure that the close cable operates correctly and can close the
carburetor fully.
Figure 5
6. Screamin’ Eagle Backplate (Twin Cam)
A. Insert the enclosed large O-ring into the Mikuni
adapter. Assemble to the Screamin’ Eagle backplate.
Use thread lock on each of the stock bolts.
B. The remainder of the Mikuni/Screamin’ Eagle installation follows the Harley instructions. We recommend
that you follow those directions to complete the air
cleaner installation (Figure 6).
A. Rotate the throttle grip to the full open position and
check to see that the throttle valve (slide) opens completely by looking into the carburetor bore. If the throttle
valve doesn’t open fully, unscrew the adjuster on the
opening cable until it does. This adjustment should be
made carefully to get the maximum performance from
the carburetor. After the adjustment is made, tighten the
adjuster jam nut.
B. After adjusting the opening cable, turn the handlebars
to the right and adjust the throttle free-play with the
closing cable to approximately 1/8” (Figure 8).
Figure 8
9. Air Cleaners (Evo & Twin Cam)
Evolution 1340 Air Cleaner Cover:
Remove the seal from the stock air cleaner cover and
attach it to the Mikuni cover.
NOTE:
Do not use the stock Evo air cleaner cover because it will restrict
the airflow and may cause a rich condition at full throttle.
Figure 6
EK-4
Twin Cam 88 Air Cleaner Cover:
Install the stock air cleaner cover to the backplate; make
sure the seal is in place.
NOTE:
To properly maintain the HSR’s performance, we recommend
that the air cleaner be inspected at 5,000-mile intervals. Clean or
replace the filter as necessary.
12. Starting
A. Re-connect the battery at this time and re-assemble the
remainder of the motorcycle.
B. Turn the fuel petcock on and start the motorcycle as you
normally would.
C. After the engine is warmed up adjust the idle to the
recommended idle speed of 1,000 to 1,100 rpm.
NOTE:
10. Hose Routing
Route the carburetor overflow hose from the bottom of the
float bowl behind the rear push rod tubes and in between
the crankcase and transmission. Do not connect to any
other hose.
CAUTION
1. If you are not using the V.O.E.S., seal the Vacuum Fitting on
the carburetor.
2. The Vent Fitting located above the Fuel Fitting must not be
sealed! Sealing it results in erratic air/fuel mixture ratios, poor
performance and possible engine damage.
NOTE:
You will notice that in many instances you will have some
remaining hoses. Since this is a performance application only, any
remaining hoses and related hardware can be removed, as they
are not required.
11. Choke Cable
A. When installing the choke cable be sure that there are
no sharp bends in the cable. Mount the choke cable
to the bracket. Do not over-tighten the nut to prevent
breakage.
B. After mounting the choke cable, check the free-play.
Loosen the knurled plastic friction nut behind the choke
knob for this test (Figure 9).
NOTE:
If there is no free-play, the engine may run rich and cause poor
performance or low fuel mileage.
Loosen the plastic friction nut only as much as necessary to free
the choke shaft. If the nut is turned out too far, its center portion
will interfere with your ability to detect free-play.
Figure 9
’95 to present models are equipped with a vacuum petcock. It
may be necessary to crank the engine over several times before
fuel flows to the carburetor.
Parts List for 42-7 and 42-18
Part#
TM42-6
HS42/001
HS42/002
HS42/003
HS42/006
HS42/070
HS42/071
HS42/072
Z70/073
N100.604-155
N100.604-165
Z70/045
Z70/146
Description
Carburetor
Adapter
Screw, Adapter
O-ring (Large)
Cover, Cleaner
Spacer
O-ring
Gasket
Cable Lube
Main Jet
Main Jet
Hose Clamp
Cable Tie
Qty HSR Kit
1
1
3
1
1
2
2
1
1
1
1
1
3
7, 18
7, 18
7
7, 18
7
18
18
18
7, 18
7, 18
7, 18
7, 18
7, 18
NOTES:
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
EK-5
#
PART NO.
1. C5=0410-B
2. CW2=0414-B
3. 776-39005
4. TM42/04
5. BS32/126
6. 826-03002
7. J8-8DDY01-97
7a. J8-8CFY02-97
8. TM42/03
8a. TM42/08-1A
9. B40I/56
10. B40I/10
11. 834-23041
12. TM42/08-3.0
13. 739-13002
14. TM42/16
15. TM42/13
15a. TM48/02
16. TM42/10
17. 925-98006
18. 53974
19. TM42/51
19a. TM42/53
20. B3=0520-B
21. VM28/204
22. TM42/38
23. C2=0514-B
24. 640-12001
25. VM14/241
26. N189.192
27. TM42/06
27a. TM48/02
28. 616-94029
29. 925-19011
30. TM42/43
31. N138.019
32. TM42/48
33. M12F/46-BB
34. MC-0316-B
35. TM42/47
36. TM42SS1/01-0
36a. TM48SS1/01
37. B36/95
38. TM42/36
39. B30/205
40. TM40/89
40a. TM42/17
41. BN38/43
42. TM42/46
43. B30/1069
44. N3=04
45. TM42/19
46. 700-15012
47. TM42/15
48. C2=0410-B
49. 604-26014
50. N133.206
HSR PARTS LIST
DESCRIPTION
Screw, Top Cover
Screw, Top Cover
Top Cover
Gasket, Top Cover
E-Ring, Jet Needle
Washer, Jet Needle
Jet Needle (42)
Jet Needle (45/48)
Lever, T.V. (42/45)
Lever, T.V. (48)
E-Ring, Link Lever
Packing, Link Lever
Pin, Link Lever
Throttle Valve (Slide)
Screw, Needle Retainer
Clip, Needle Retainer
Sealing Ring, T.V. (42/45)
Sealing Ring, T.V. (48)
Seal, Throttle Valve
Pulley, Cable Bracket
E-Ring, Cable Bracket
Bracket Ass’y, Cable
Bracket Ass’y, Sportster
Bolt, Bracket
Spacer, Bracket
Plate, Lock Tab
Screw
Starter Nut, Choke
Spring, Starter Plunger
Starter Plunger
Body, Bearing & Spigot (42/45)
Body, Bearing & Spigot (48)
Seal, Spigot Body
Ring (Steel)
Lever, A/P
Pin, Throttle Lever
Lever, Throttle
Spring, A/P
Screw, A/P
Spring, A/P
Mixing Body (42/45)
Mixing Body (48)
Packing, Shaft (Plastic)
Adjusting Screw, A/P
O-Ring, A/P Screw
Bolt
Plate, Lock Tab for Shaft
Pin, Return Lever
Lever, Return
Adjusting Screw, Throttle
Nut, Throttle Stop
Spring, Throttle Return
Shaft, Throttle
Plate, Fuel Joint Retainer
Screw, Fuel Joint
Screw, Pilot Air
Spring, Pilot Air
51. VM12/205
52. N133.037
53. TM40/27
54. KV/10
55. B30/398
56. VM22/138
57. 730-09018
58. 925-15001
59. TM42/32
59a. 990-605-065
60. BS30/97-00
61. 784-430000-Y-6
62. TM42/11-70
63. N124.063
64. VM28/486-25
65. TM42/12
65a. TM42/12-1A
66. N100.604-160
67. 616-33003
68. VM13/216
69. 786-27001-4.2
69a. 786-27002-1A
70. 859-32027
71. BV26/22
72. C2=0410
73. 616-94028
74. TM42/05
75. N122.028
76. VM28/254
77. TM32/41
77a. TM32/41-1D
78. C2=0412-B
79. TM36/44-1A
80. TM36/64
81. TM36/60
82. VM14SC13/89
83. N198.063
Washer, Pilot Air
O-Ring, Pilot Air
Fuel Joint
O-Ring, Fuel Joint
Packing, Idle Adjuster
Washer, Idle Adjuster
Spring, Idle Adjuster
Ring,Idle Adjuster
Idle Adjuster (Long)
Idle Adjuster (Short)
Air Jet (Blank)
Needle Jet (723)
Nozzle, Accel. Pump
O-Ring, A/P
Pilot Jet
Extender, Main Jet (42/45)
Extender, Main Jet (48)
Main Jet
O-Ring N.V.
Screw, N.V. Retainer
Needle Valve Ass’y (42/45)
Needle Valve Ass’y (48)
Float Ass’y
Pin, Float
Screw, Float Pin
Packing, Float Bowl
Float, Chamber Body
Hose, Overflow
O-Ring, Drain Plug
Drain plug (42/45)
Drain Plug (48)
Screw, Flt Bowl, short
Rod, A/P
Boot, A/P Rod
Plunger, A/P
Spring, A/P
Rubber Cap, Purge Port
Alternate Parts
Jet Needles:
HSR42
HSR45/48
J8-8DDY01-95 J8-8CFY02-95 Richer
J8-8DDY01-96 J8-8CFY02-96 Richer
J8-8DDY01-97 J8-8CFY02-97 Std
J8-8DDY01-98 J8-8CFY02-98 Leaner
Accelerator Pump Nozzles:
TM42/11-70
Std
TM42/11-60
Leaner
TM42/11-50
Leaner
Needle Valve Assemblies:
786-27002-1A-4.5 Std (HSR48)
786-27001-4.2
Std (HSR42/45)
786-27001-3.5
Smaller
NOTE:
786-27001-2.3
Pressure only
Rebuild Kit:
HSR42/45: KHS-016
HSR48:
KHS-031
1. Lined through part
numbers are not
available.
2. Parts in bold are
included in rebuild
kits.
EK-6
Mikuni American Corporation
8910 Mikuni Avenue
Northridge, CA 91324-3496
www.mikuni.com
#
PART NO.
DESCRIPTION
1. C5=0410-B
Screw, Top Cover
2. CW2=0414-B Screw, Top Cover
3. 776-39005
Top Cover (42/45)
3a. 111-776-001 Top Cover (HSR48)
4. TM42/04
Gasket, Top Cover
5. BS32/126
E-Ring, Jet Needle
6. 82603002
Washer, Jet Needle
7. J8-8DDI01-97 Jet Needle (42)
7a. J8-8CFY02-97 Jet Needle (45/48)
8. TM42/03
Lever, T.V. (45/48)
8a. TM42/08-1A Lever, T.V. (HSR48)
9. B401/56
E-Ring, Link Lever
10. B40I/10
Packing, Link Lever
11. 834-23041
Pin, Link Lever
12. TM42/08-3.0 Throttle Valve (Slide)
13. 739-13002
Screw, Needle Retainer
14. TM42/16
Clip, Needle Retainer
15. TM42/13
Sealing Ring, T.V. (42/45)
15a. TM48/02
Sealing Ring, T.V. (48)
16. TM42/10
Seal, Throttle Valve
17. 925-98006
Pulley, Cable Bracket
18. 53974
E-Ring, Cable Bracket
19. TM42/51
Bracket Ass’y, Cable
19a. TM42/53
Bracket Ass’y, Sportster
20. B3=0520-B Bolt, Bracket
21. VM28/204
Spacer, Bracket
22. TM42/38
Plate, Lock Tab
23. C2-0514-B
Screw
24. 640-12001
Starter Nut, Choke
25. VM14/241
Spring, Starter Plunger
26. N189.192
Starter Plunger
27. TM42/06
Body (HSR42/45)
27a. TM48/02
Body (HSR48)
28. 616-94029
Seal, Spigot Body
29. 925-19011
Ring (Steel)
30. TM42/43
Lever, A/P
31. N138.019
Pin, Throttle Lever
32. TM42/48
Lever, Throttle
33. M12F/46-BB Spring, A/P
34. MC-0316-B Screw, A/P
35. TM42/47
Spring, A/P
36. TM42SS1/01-0 Mixing Body (42/45)
36a. TM48SS1/01 Mixing Body (48)
37. B36/95
Packing, Shaft (Plastic)
38: TM42/36
Adjusting Screw, A/P
39. B30/205
ORing, A/P Screw
40. TM40/89
Bolt
40a. TM42/17
Plate, Lock Tab for Shaft
41. BN38/43
Pin, Return Lever
42. TM42/46
Lever, Return
43. B30/1069
Adjusting Screw, Throttle
44. N3=04
Nut, Throttle Stop
45. TM42/19
Spring, Throttle Return
46. 700-15012
Shaft, Throttle
47. TM42/15
Plate, Fuel Joint Retainer
48. C2-0410-B
Screw, Fuel Joint
49. 604-26014
Screw, Pilot Air
50. N133.206
Spring, Pilot Air
51. VM12/205
Washer, Pilot Air
52. N133.037
ORing, Pilot Air
53. TM40/27
Fuel Joint
54. KV/10
O-Ring, Fuel Joint
55. B30/398
Packing, Idle Adjuster
56. VM22/138
Washer, Idle Adjuster
57. 730-09018
Spring, Idle Adjuster
58. 925-15001
Ring, Idle Adjuster
59. TM42/32
Idle Adjuster (Long)
59a. 990-605-065 Idle Adjuster (Short)
60. BS30/97-00 Air Jet (Blank)
61. 784-430000-Y-6 Needle Jet (723)
62. TM42/11-70 Nozzle, Accel, Pump
63. N124.063
O-Ring, A/P
64. VM28/486-25 Pilot Jet
65. TM42/12
Extender, Main Jet (42/45)
65a. TM42/12-1A Extender, Main Jet (48)
66. N100.604-160 Main Jet
67. 616-33003
O-Ring N.V.
68. VM13/216
Screw, N.V. Retainer
69. 786-27001-4.2 Needle Valve Ass’y (42/45)
69a. 786-27002-1A Needle Valve Ass’y (48)
70. 859-32027
Float Ass’y
71. BV26/22
Pin, Float
72. C2=0410
Screw, Float Pin
73. 616-94028
Packing, Float Bowl
74. TM42/05
Float, Chamber Body
75. N122.028
Hose, Overflow
76. VM28/254
O-Ring, Drain Plug
77. TM32/41
Drain plug (42/45)
77a. TM32/41-1D Drain plug (48)
78. C2=0412-B Screw, Flt Bowl, short
79. TM36/44-1A Rod, A/P
80. TM36/64
Boot, A/P Rod
81. TM36/60
Plunger, A/P
82. VM14SC13/89 Spring, A/P
83. N198.063
Rubber Cap, Purge Port
Alternate Parts
Jet Needles:
HSR42
J8-8DDY01-95
J8-8DDY01-96
J8-8DDY01-97
J8-8DDY01-98
HSR45/48
J8-8CFY02-95
Richer
J8-8CFY02-96
Richer
J8-8CFY02-97
Std
J8-8CFY02-98
Leaner
Accelerator Pump Nozzles:
TM42/11-70
Std
TM42/11-60
Leaner
TM42/11-50
Leaner
Needle Valve Assemblies:
786-27002-1A-4.5 Std (HSR48)
786-27001-4.2
Std (HSR42/45)
786-27001-3.5
Smaller
786-27001-2.3
Pressure feed only
Rebuild Kit:
HSR42/45: KHS-016
HSR48:
KHS-031
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