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Tuning Manual
Revised 02/10/03
2
NOTE: NOTE:
The procedures described below It is important that you use a tight-
require that some gasoline be spilled. fitting screwdriver. Mikuni float bowl and
There are obvious dangers when doing top cover screws are slightly soft. This
this. is a deliberate choice: We would rather
strip screw heads than the threads of an
MAIN JET expensive aluminum casting. For this
1. Turn the fuel petcock off. same reason, we recommend against
2. Place a container under the installing hardened Allen screws.
carburetor to catch the fuel in the
carburetor and fuel line. NOTES:
3. Use an 11/16” or 17mm wrench to
remove the drain plug. _____________________________
4. Remove the jet. _____________________________
5. Replace jet. Tighten gently. _____________________________
6. Replace and tighten drain plug. _____________________________
PILOT JET _____________________________
1. Turn the fuel petcock off. _____________________________
2. Remove the drain plug and drain _____________________________
the float bowl. _____________________________
3. Remove the float bowl.
4. Remove the pilot jet (see exploded
view for location).
5. Install new jet. Start the jet by
hand. Do not over-tighten.
6. Reassemble.
ACCELERATOR PUMP NOZZLE
1. Turn the fuel petcock off .
2. Remove the drain plug and drain
the float bowl.
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CHOKE CABLE INSTALLATION Another possible cause of poor
The HSR series carburetors use mileage, rough idle and fouled spark
either of two choke cables: the stock plugs is incorrect cable routing. The
Harley-Davidson cable (1990 and stock Harley choke cable is very stiff
later) or the Mikuni cable. Mikuni and may not be fully seated in the
designed the HSR to accept the metal elbow at the carburetor end.
Harley cable to save you money and On occasion, one of these errors
because the stock cable works well. may have been made by someone
The Mikuni cable is furnished for else at another location. The unfor-
those installations that do not start tunate mechanic who inherits the
with an installed stock CV carburetor. task of correcting the rich condition,
The majority of HSR42/45 installa- poor idle and poor fuel mileage may
tions use the Harley cable. Installa- have no clue as to the mismatch of
tion is simple when the instructions parts. For this reason, we include the
are followed, step by step. Those following photos and text to help you
steps are: discover if your installation is correct.
1. Remove the stock Harley choke
cable assembly.
2. Remove the spring and plunger
from the stock cable.
3. Remove the Mikuni “Starter Nut”
from the HSR.
4. Remove the Mikuni spring and
plunger from the HSR.
5. Install the Mikuni spring and
plunger on the Harley choke cable.
6. Install the Harley choke cable with
the fitted Mikuni spring and plunger
into the HSR carburetor.
DO NOT use the Mikuni Starter Harley’s choke knob has the word
Nut; discard it. “CHOKE” in white. The Mikuni knob
DO NOT use the Harley spring or has a small brass bump in its center.
plunger; discard them.
Note: If you do not have installation
instructions, you may download them
from the “www.mikuni.com” website .
in the “manuals” section.
If the Mikuni Starter Nut is fitted to
the Harley cable, the choke plunger
is held off its seat and the choke is
open all the time. If the Harley spring
and plunger are used, the plunger
does not seal and the choke is
open all the time. The result, in both The Mikuni spring is longer and
cases, is very poor fuel mileage (30 stiffer than the Harley part.
mpg or less).
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The Mikuni nut has a smaller hole The Mikuni choke cable has an
where the cable fits and must not be adjuster; the Harley cable does not.
used with the Harley choke cable. The Mikuni threaded section is steel
The Harley nut is larger and is while Harley’s is plastic. The Mi-
knurled on its outer diameter. kuni cable has a hold-open detent;
Harley’s cable has a friction adjuster.
The Mikuni knob has a small brass
center while Harley’s has the word
“CHOKE” in white.
Jet Needle:
NOTES: Throttle range: 1/8 - 3/4
HSR42 HSR45/48
_____________________________ Richer: J8-8DDY01 - 95 J8-8CFY02 - 95
_____________________________ Richer: J8-8DDY01 - 96 J8-8CFY02 - 96
_____________________________ Std: J8-8DDY01 - 97 J8-8CFY02 - 97
_____________________________ Leaner: J8-8DDY01 - 98 J8-8CFY02 - 98
_____________________________
_____________________________ Standard HSR Jet Needle straight
_____________________________ diameter portion is 2.97 mm. This
portion of the needle affects tuning
from idle to approximately 1⁄4 throttle
opening.
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Accelerator Pump Nozzles
Leaner TM42/11–50
NOTES:
Std. for Sportster TM42/11–60
_________________
Standard TM42/11–70
_________________
__________________
Mikuni Jet Kit
__________________
Tuning Kit: HSR42: KHS–025
_________________
Jet Kit Contains:
_________________
(18) Main Jets (2 each 150 thru 170)
___________________________
(10) Pilot Jets (2 each 20 thru 32.5)
____________________________
(3) Needles:–96, –97, –98 (42 only)
_________________
(2) Pump Nozzle (#60)
_________________
(4) Needle E-Ring Clips & Washers
___________________________
(2) O-ring, Pump Nozzle(N124.063)
(1) Plastic Box
____________________________
HSR42/45 Carb Rebuild Kit
Carb Rebuild Kit: KHS–016
See exploded view drawing for con-
tents.
NOTE:
Do not modify the idle screw or any of
its component parts. If you remove the
screw, be sure to re-install it with the
components in place as illustrated in the
exploded view.
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17
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# PART NO. DESCRIPTION 50. N133.206 Spring, Pilot Air
1. C5=0410-B Screw, Top Cover 51. VM12/205 Washer, Pilot Air
2. CW2=0414-B Screw, Top Cover 52. N133.037 ORing, Pilot Air
3. 776-39005 Top Cover (42/45) 53. TM40/27 Fuel Joint
3a. HS42/081 Top Cover (HSR48) 54. KV/10 O-Ring, Fuel Joint
4. TM42/04 Gasket, Top Cover 55. B30/398 Packing, Idle Adjuster
5. BS32/126 E-Ring, Jet Needle 56. VM22/138 Washer, Idle Adjuster
6. 826-03002 Washer, Jet Needle 57. 730-09018 Spring, Idle Adjuster
7. J8-8DDY01-97 Jet Needle (42) 58. 925-15001 Ring, Idle Adjuster
7a. J8-8CFY02-97 Jet Needle (45/48) 59. TM42/32 Idle Adjuster (Long)
8. TM42/03 Lever, T.V. (42/45) 59a. 990-605-065 Idle Adjuster (Short)
8a. TM42/08-1A Lever, T.V. (HSR48) 60. BS30/97-00 Air Jet (Blank)
9. B40I/56 E-Ring, Link Lever 61. 784-430000-Y-6 Needle Jet (723)
10. B40I/10 Packing, Link Lever 62. TM42/11-70 Nozzle, Accel, Pump
11. 834-23041 Pin, Link Lever 63. N124.063 O-Ring, A/P
12. TM42/08-3.0 Throttle Valve (Slide) 64. VM28/486-25 Pilot Jet (Sportster - 20)
13. 739-13002 Screw, Needle Retainer 65. TM42/12 Extender, Main Jet (42/45)
14. TM42/16 Clip, Needle Retainer 65a. TM42/12-1A Extender, Main Jet (48)
15. TM42/13 Sealing Ring, T.V. (42/45) 66. N100.604-160 Main Jet (45-175, 48-190)
15a. TM48/02 Sealing Ring, T.V. (48) 67. 616-33003 O-Ring N.V.
16. TM42/10 Seal, Throttle Valve 68. VM13/216 Screw, N.V. Retainer
17. 925-98006 Pulley, Cable Bracket 69. 786-27001-4.2 Needle Valve Ass’y (42/45)
18. 53974 E-Ring, Cable Bracket 69a. 786-27002-1A Needle Valve Ass’y (48)
19. TM42/51 Bracket Ass’y, Cable 70. 859-32027 Float Ass’y
19a. TM42/53 Bracket Ass’y, Sportster 71. BV26/22 Pin, Float
20. B3=0520-B Bolt, Bracket 72. C2=0410 Screw, Float Pin
21. VM28/204 Spacer, Bracket 73. 616-94028 Packing, Float Bowl
22. TM42/38 Plate, Lock Tab 74. TM42/05 Float, Chamber Body
23. C2=0514-B Screw 75. N122.028 Hose, Overflow
24. 640-12001 Starter Nut, Choke 76. VM28/254 O-Ring, Drain Plug
25. VM14/241 Spring, Starter Plunger 77. TM32/41 Drain plug (42/45)
26. N189.192 Starter Plunger 77a. TM32/41-1D Drain plug (48)
27. TM42/06 Body (HSR42/45) 78. C2=0412-B Screw, Flt Bowl, short
27a. TM48/02 Body (HSR48) 79. TM36/44-1A Rod, A/P
28. 616-94029 Seal, Spigot Body 80. TM36/64 Boot, A/P Rod
29. 925-19011 Ring (Steel) 81. TM36/60 Plunger, A/P
30. TM42/43 Lever, A/P 82. VM14SC13/89 Spring, A/P
31. N138.019 Pin, Throttle Lever 83. N198.063 Rubber Cap, Purge Port
32. TM42/48 Lever, Throttle
Alternate Parts
33. M12F/46-BB Spring, A/P
Jet Needles:
34. MC-0316-B Screw, A/P
HSR42 HSR45/48
35. TM42/47 Spring, A/P
J8-8DDY01-95 J8-8CFY02-95 Richer
36. TM42SS1/01-0 Mixing Body (42/45)
J8-8DDY01-96 J8-8CFY02-96 Richer
36a. TM48SS1/01 Mixing Body (48)
J8-8DDY01-97 J8-8CFY02-97 Std
37. B36/95 Packing, Shaft (Plastic)
J8-8DDY01-98 J8-8CFY02-98 Leaner
38: TM42/36 Adjusting Screw, A/P
Accelerator Pump Nozzles:
39. B30/205 ORing, A/P Screw
TM42/11-70 Std
40. TM40/89 Bolt
TM42/11-60 Leaner
40a. TM42/17 Plate, Lock Tab for Shaft
TM42/11-50 Leaner
41. BN38/43 Pin, Return Lever
Needle Valve Assemblies:
42. TM42/46 Lever, Return
786-27002-1A-4.5 Std (HSR48)
43. B30/1069 Adjusting Screw, Throttle
786-27001-4.2 Std (HSR42/45)
44. N3=04 Nut, Throttle Stop
786-27001-3.5 Smaller
45. TM42/19 Spring, Throttle Return
786-27001-2.3 Pressure feed only
46. 700-15012 Shaft, Throttle NOTE:
Rebuild Kit:
47. TM42/15 Plate, Fuel Joint Retainer 1. Lined through part num-
HSR42/45: KHS-016 bers are not available.
48. C2=0410-B Screw, Fuel Joint
HSR48: KHS-031 2.inParts in bold are included
rebuild kits.
49. 604-26014 Screw, Pilot Air
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Mikuni American Corporation
8910 Mikuni Avenue
Northridge, CA
91324-3496
www.mikuni.com
818-885-1242