IH: Carburetor, Intake Manifold & Exhaust - Sub-01E

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====== IH: Carburetor, Intake Manifold & Exhaust - Sub-01E ======
\\
====== Tillotson Carb Identification ======
See also in the Sportsterpedia: \\
  * [[techtalk:ih:carb01#tillotson_hd_carb_1966-1971|Tillotson Carb Basic Information]]
  * [[techtalk:ih:carb01f|Rebuilding the Tillotson Carb]]
  * [[techtalk:ih:carb01g|Tillotson Carb Functions, Adjustments, Tuning]]

====== Tillotson Carbs by Serial/Model Number ======
|**Tillotson HD (1966-1971)**||
|Model  HD-1A \\ Model HD-1B|Pre-1966 XLCH \\ 1966-later XLCH|
|27162-66B((Shop Dope Vol 4 Service Bulletin No 571 May 21, 1968)) \\ HD - 1BC \\ HD - 1C|Late '68 Sportsters (new check ball valve added to the accel pump passage)) ((Shop Dope Vol 4 Service Bulletin No 571 May 21, 1968)) |
|27155-66RA \\ HD5A| 900 (XLR) (27823-66R)| 
|27155-70R \\ HD5A| 750 (XR) (27823-66R)|

Early 66 (1966 model), HD1A: diaphragm lever and fuel valve without fork. Fuel valve brought down by gravity only. ((thefrenchowl of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/84622-question-to-16p12-carb-66-xlch-intro/page2?t=640864&page=2)) \\
Oct 1966 sheet (1967 model), HD1B: fork on diaphragm lever for positive opening and closing of fuel valve. \\
Sorted leaning out of mixture at high revs due to earlier design and vibrations (from Aug 10th, engine 66X***(*)10611) \\
Jan 1968 sheet, HD1BC or HD1C: added little ball valves in the plastic cover for accelerator pump circuit to improve action. \\
It does not rely anymore on just the little rubber valve flaps on the gasket. \\
Improved accelerator pump delivery. Also added economizer ball in main jet circuit for improved mileage
The later version was HD1D. \\
Most Tillies out there, even if stamped with earlier numbers, possibly would have been modded to later specs if properly serviced at the dealers at the time. \\
These carbs will start the engine easier if they're flooded: \\
Attach a small nylon cable tie underneath carb from one of the cover screws. \\
You can then poke (tickle) the diaphragm up through the vent hole in the middle of the plastic cover to flood it. Or adapt a tickler from a GB Amal carb. \\

{{:techtalk:ih:carb:tillotson_id_by_dr_dick.jpg?direct&300|}} ((photo by 16ouncePBR of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/126126-satan-s-bagger-a-1968-xlh-resto/page6?t=1276189&page=6)) \\

===== Tillotson HD1A =====
The Linkert cable bracket is correct for 66 as is the no drill point phenolic insulator (one year only). ((Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) \\
67 was 1st year for the over the top bracket and the drill point. The pn did not change for the drill point (all blocks made from 67 up are drilled). \\
Full choke closed detent in 66 shafts are not as 'positive' as 67-71. Also the "wraparound" cable bracket is 67-71. \\
As far as the phenolic block, 66 no-drill point, E67ch & 67-71H, 70-71 CH-drill point. L67-69CH block gets longer bottom stud for plug wire router. \\

{{:techtalk:ih:carb:tillotson_hd1a_pic_1_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) {{:techtalk:ih:carb:tillotson_hd1a_pic_2_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) {{:techtalk:ih:carb:tillotson_hd1a_pic_3_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted?t=1567534)) \\
===== Tillotson HD1C =====

{{:techtalk:ih:carb:tillotson_hd1c_pic_4_by_81fe.jpg?direct&300|}} ((photo by 81Fe of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/101016-my-1969-xlch-restoration-thread-lots-of-progess-pics/page7?t=872908&page=7)) \\

{{:techtalk:ih:carb:tillotson_hd1c_pic_1_by_81fe.jpg?direct&300|}} ((photo by 81Fe of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/101016-my-1969-xlch-restoration-thread-lots-of-progess-pics/page5?t=872908&page=5)) {{:techtalk:ih:carb:tillotson_hd1c_pic_2_by_81fe.jpg?direct&300|}} ((photo by 81Fe of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/101016-my-1969-xlch-restoration-thread-lots-of-progess-pics/page5?t=872908&page=5)) {{:techtalk:ih:carb:tillotson_hd1c_pic_3_by_81fe.jpg?direct&300|}} ((photo by 81Fe of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/101016-my-1969-xlch-restoration-thread-lots-of-progess-pics/page5?t=872908&page=5)) \\

This one is marked HD1C D: \\
Notice the 'D' wasn't stamped at the same time as the rest. Most likely a 'C' upgraded to a 'D'. The date code is E69. \\
{{:techtalk:ih:carb:tillotson_hd1c_d_pic_3_by_simeli.jpg?direct&300|}} ((photo by simeli of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) {{:techtalk:ih:carb:tillotson_hd1c_d_pic_1_by_simeli.jpg?direct&300|}} ((photo by simeli of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) {{:techtalk:ih:carb:tillotson_hd1c_d_pic_2_by_simeli.jpg?direct&300|}} ((photo by simeli of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/144565-disaster-averted/page4?t=1567534&page=4)) \\

===== Tillotson HD1D =====
HD1D from a 1971 XLCH: \\

{{:techtalk:ih:carb:tillotson_hd1d_pic_1_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/166320-need-pics-of-carbs/page2?t=1786621&page=2)) {{:techtalk:ih:carb:tillotson_hd1d_pic_9_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM)){{:techtalk:ih:carb:tillotson_hd1d_pic_12_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/166320-need-pics-of-carbs/page2?t=1786621&page=2)) \\

{{:techtalk:ih:carb:tillotson_hd1d_pic_11_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/166320-need-pics-of-carbs/page2?t=1786621&page=2)) {{:techtalk:ih:carb:tillotson_hd1d_pic_10_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/166320-need-pics-of-carbs/page2?t=1786621&page=2)){{:techtalk:ih:carb:tillotson_hd1d_pic_6_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM)) \\

{{:techtalk:ih:carb:tillotson_hd1d_pic_5_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM)) {{:techtalk:ih:carb:tillotson_hd1d_pic_3_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM)){{:techtalk:ih:carb:tillotson_hd1d_pic_4_by_the_doctor71.jpg?direct&200|}} ((Pic courtesy of The Doctor71 of the XLFORUM)) \\

{{:techtalk:ih:carb:tillotson_hd1d_pic_2_by_the_doctor71.jpg?direct&250|}} ((Pic courtesy of The Doctor71 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/166320-need-pics-of-carbs/page2?t=1786621&page=2)) {{:techtalk:ih:carb:tillotson_hd1d_pic_7_by_the_doctor71.jpg?direct&250|}} ((Pic courtesy of The Doctor71 of the XLFORUM)){{:techtalk:ih:carb:tillotson_hd1d_pic_8_by_the_doctor71.jpg?direct&250|}} ((Pic courtesy of The Doctor71 of the XLFORUM)) \\

===== Tillotson HD5A =====
HD5A's are racing carbs used on KR, XR, XLR and other race bikes. \\
It has no accelerator pump and a metal diaphragm bottom cover. ((Ferrous Head of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/27123-iron-1966-xlrtt/page30?t=44897&highlight=hd5a&page=30)) \\

Click on any pic below to enlarge: Photos courtesy of Robert Evans. \\

{{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic1_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic2_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic3_by_robert_evans.jpg?direct&300|}} \\

{{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic4_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic5_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic6_by_robert_evans.jpg?direct&300|}} \\

{{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic7_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic8_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic9_by_robert_evans.jpg?direct&300|}} \\

{{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic10_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic11_by_robert_evans.jpg?direct&300|}} {{:techtalk:ih:carb:1969_tillotson_hd5a_carburetor_pic12_by_robert_evans.jpg?direct&300|}} \\
===== Andrews Super 45 =====
The Andrews Super 45 is basically a Tillotson bored out to 45mm with a 45mm butterfly in it. ((Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) \\

AP-45-2: \\
{{:techtalk:ih:carb:andrews_ap452_pic_2_by_dr_dick.jpg?direct&200|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/109699-hot-rod-parts-thread/page7?t=1022912&page=7)) {{:techtalk:ih:carb:andrews_ap452_pic_1_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/109699-hot-rod-parts-thread/page7?t=1022912&page=7)) {{:techtalk:ih:carb:andrews_ap452_pic_3_by_dr_dick.jpg?direct&300|}} ((photo by Dr Dick of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/109699-hot-rod-parts-thread/page7?t=1022912&page=7)) \\

HD137B 548 ("C" version): \\
{{:techtalk:ih:carb:andrews_super_45_carb_1_by_hopper.jpg?direct&250|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) {{:techtalk:ih:carb:andrews_super_45_carb_2_by_hopper.jpg?direct&250|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) \\

{{:techtalk:ih:carb:andrews_super_45_carb_3_by_hopper.jpg?direct&250|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) {{:techtalk:ih:carb:andrews_super_45_carb_4_by_hopper.jpg?direct&250|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) \\

{{:techtalk:ih:carb:andrews_super_45_carb_6_by_hopper.jpg?direct&200|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) {{:techtalk:ih:carb:andrews_super_45_carb_7_by_hopper.jpg?direct&200|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) {{:techtalk:ih:carb:andrews_super_45_carb_8_by_hopper.jpg?direct&200|}} ((photo by Hopper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/64117-andrews-super-45-carburetor?t=399267)) \\

====== Throttle Cable ======

{{:techtalk:ih:carb:tillotson_bracket_by_magneto_sportster.jpg?direct&300|}} ((photo by Magneto Sportster of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/54175-need-pic-of-tillotson-cable-bracket?t=258048)) {{:techtalk:ih:carb:tillotson_carb_4_by_ridered67.jpg?direct&300|}} ((photo by RIDERED67 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/120319-67-xlh-restore-finished-need-carb-help/page4?t=1173719&page=4)) {{:techtalk:ih:carb:tillotson_carb_5_by_ridered67.jpg?direct&300|}} ((photo by RIDERED67 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/120319-67-xlh-restore-finished-need-carb-help/page4?t=1173719&page=4)) \\

====== Tillotson HD Parts List ======
 
^  1966 Tillotson HD Parts List for Sportsters  ||
|27162-66|CARBURETOR (complete)|
|711|WELCH PLUG, body (2)|
|712|WELCH PLUG, choke lever|
|713|WELCH PLUG, check ball|
|993W|SCREW, throttle wire, No. 6-32 x 1/4 fil. hd.|
|2540|SCREW, pump lever, No. 4-36 x 1/4 fil. lid.|
|7005|LOCKWASHER, pump lever screw, No. 4|
|27135-66|REPAIR PARTS KIT|
|27138-66|GASKET SET|
|27352-66|SCREW, intermediate speed adj.|
|27353-66|PACKING RING, intermediate speed adj. screw|
|27354-66|WASHER, intermediate speed adj. screw|
|27406-26|BALL, choke shaft friction spring|
|27407-66|CHECK BALL|
|2594-66|INLET FITTING, carburetor (2)|
|27595-66|PIN, inlet valve lever|
|27596-66|RETAINING SCREW, inlet valve lever pin|
|27597-66|INLET NEEDLE, SEAT AND GASKET|
|27598-66|GASKET, inlet seat|
|27599-66|SPRING, inlet valve lever|
|27615-66 MAIN JET — .057 in.|
|27658-66|CHECK VALVE ASSEMBLY|
|27661-66|SEAL, choke shaft|
|27668-66|CHOKE SHUTTER RELIEF VALVE|
|27669-66|SPRING, choke relief valve|
|27671-66|FRICTION SPRING, choke shaft|
|27673-66|CHOKE SHUTTER|
|27688-66|SCREW, intermediate speed adjusting|
|27689-61|SPRING, idle and intermediate adj. screws (2)|
|27691-59|SPRING, throttle lever stop|
|27704-61|PLUG SCREW, main jet|
|27706-66|SPRING, throttle shaft|
|27707-66|SEAL, throttle shaft|
|27708-66|THROTTLE SHAFT AND LEVER|
|27712-66|SEAL WASHER, throttle shaft|
|27714-66|THROTTLE DISC|
|27717-66|SCREW, throttle lever stop|
|27718-66|CHOKE SHAFT AND LEVER|
|27720-61|SCREW WITH LOCKWASHER, choke & throttle shutters (4)|
|27740-63|LEVER, inlet valve|
|27746-66|INLET SCREEN (2)|
|27747-66|CUP, idle adj. screw|
|27759-66|LEVER, accelerating pump|
|27760-66|ACCELERATING PUMP|
|27804-66|DIAPHRAGM COVER|
|27806-66|GASKET, diaphragm cover|
|27812-66|PLUG SCREW, diaphragm cover|
|27814-66|RETAINING SCREW, diaphragm cover (6)|
|27816-66|DIAPHRAGM|

===== Links,Parts and Services for Tillotson Carbs =====

Original P/N for a Sporty Tillotson repair parts kit 27147-66 ((rivethog of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/ironhead-sportster-motorcycle-talk-1957-1985/92522-another-tillotson-magneto-hard-to-start-xlch-question/page2?t=757993&page=2)) \\
Original P/N for a Big Twin Tillotson repai parts kit 27137-66 \\

  * Parts list for Tillotson HD carbs:
      * [[http://tillotson.ie/wp-content/uploads/2015/07/HD-Series-1-Parts-List.pdf|HD Series 1 Parts List (PDF)]]
      * [[http://tillotson.ie/wp-content/uploads/2015/07/HD-Series-2-Parts-List.pdf|HD Series 2 Parts List (PDF)]]
  * Service manual for Tillotson carbs:
      * [[http://tillotson.ie/wp-content/uploads/2016/03/Tillotson-HD-Series-Carburetor.pdf|Tillotson HD Series Carburetor (PDF)]]
  * Servicing for Tillotson carbs:
      * [[http://tillotson.ie/market/vintage/?filters=product_cat[repair-kits-parts]|Tillotson Company]].
      * [[https://www.eccarburetors.com/|EC Carburetors]]. 
      * [[http://thecarburetorshop.com/|The Carburetor Shop]].


|{{techtalk:ih:carb:tillotson_carb_repair_kit_by_the_doctor71_of_the_xlforum.jpg?direct&300|}}|
|Tillotson Carburetor repair/ refresh kit((Pic courtesy of The Doctor71 of the XLFORUM))|


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Trace: • REF: Service Procedures 11L • IH: Electrical System - Sub-03A • EVO: Suspension - Sub-02A • EVO: Electrical System - Sub-03G • EVO: Carburetor, Intake Manifold & Exhaust • MiscRes: Magazine Articles • REF: Body Parts • REF: Body Parts • REF: Body Parts - Sub-30B • REF: Oiling & Lubrication - Sub-05H