Rebuilding the carb for the 90 Sportster…

In my last post I disassembled the new to me CV carburetor which will replace the carburetor I took off the 90 Sportster to use on the 88 Sportster. The carburetor has been in the ultrasonic cleaner, then rinsed with hot water. After a good rinse I blew out the passages with compressed air. The carburetor is clean, now to rebuild it.

I am using an All Balls Racing Carburetor Rebuild Kit to rebuild the carburetor. Replaced the emulsion tube and jets. I am using a 48 pilot and a 180 main jet. The jets may need to be changed for tuning, but the 48 and 180 are where I am starting. All the gaskets and o-rings are replaced. New float needle and new guts for the accelerator pump. I am installing a thumb screw mixture adjustment screw. New hardware to put the float bowl, accelerator pump cover, and top cover back together.

I really like the All Balls Racing Carburetor Rebuild Kits. You can find less expensive carburetor rebuild kits out there, but the All Balls Racing kits are the most complete kits I have found and include high quality components.
All Balls Racing Carburetor Rebuild Kit
The All Balls Racing Carburetor Rebuild Kit includes:

  • 4 x Float Bowl Screws
  • 3 x Accelerator Pump Cover Screws
  • 3 x Carburetor Top Cover Screws
  • 2 Different Float Bowl Gaskets (I think one of the bowl gaskets is for a carburetor without an accelerator pump)
  • Float Needle
  • Accelerator Pump Diaphragm
  • Accelerator Pump Spring
  • Accelerator Pump O-Ring
  • Accelerator Pump Boot
  • Drain Plug O-ring
  • 3 Main Jets (175, 180, 185)
  • 3 Pilot Jets (42, 45, 48)
  • Emulsion Tube
  • Needle
  • Mixture Screw
  • Mixture Screw Spring, Washer, and O-ring
  • Intake Manifold Gaskets (2 x intake to heads, 1 x intake to carburetor)
  • 2 Air Cleaner Gaskets

If you are doing a full rebuild the All Balls Racing Kit is definitely worth the money in my opinion.

Genuine James Gasket also has a good rebuild kit but it only includes the gaskets, o-rings, float needle, and accelerator pump components, not all the other parts and pieces. So if you are just replacing gaskets and not the jets and hardware the Genuine James Gasket Carburetor Rebuild Kit is a less expensive option.

I picked up a intake manifold on eBay. It also gets new gaskets before it is installed on the bike.

Couple more things to do and then the 1990 Sportster will be back on the road.

Build. Tinker. Ride.

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