My wife has a fine example of one of the best Harley Davidsons ever made, the Sportster 883XL. I love her ride, I really do. One of the first things I did to the bike after we bought it was to install a set of Vance and Hines Big Shot pipes, an Arlen Ness Big Sucker AC kit and then upgraded the carburetor with a Dynojet jet kit.

I will review the Big Shot Pipes and the Big Sucker in a separate review and in this one we will talk about installing a jet kit for an 883 Sportster. I have included the dynojet jet kit instructions that come with the kit. These are specific to an 883XL but most are similar and you will get instructions in your kit.

Jet Kit Installation Preparation

The first thing I have to say is that if you have some concern over doing this yourself, then don't. This was so much easier to do than most people think and I would strongly encourage you to do it yourself, as long as you aren't a complete nimrod like me then you will be fine.

To prepare for the jet kit install you really won't need much. I would grab a roll of shop towels and a good size can of carb cleaner. Part of the upgrade involves drilling the slide so you will need a drill. The proper size drill bit comes in the kit but you still need the actual drill.

Clear your workspace, make sure you have a drain pan to drain the gasoline when you crack the fuel bowls off the carb and make sure you can see adequately. You will be handling a few small pieces and parts so the cleaner your shop floor or bench is then then better. Inevitably one of the small pieces will go flying and a clean floor makes it easier to find.

Sportster Jet Kit Upgrade Tips

The installation was very straightforward as I said before and you really shouldn't be intimidated by it. Just follow the instructions exactly and do it step by step. The ONLY thing that went wrong during my upgrade was I pinched the diaphragm on the slide when I reinstalled.

Fortunately it didn't rip it and I reseated and screwed it back together and voila. One piped and jetted little 883 ready for battle. Significant difference in power on the Sportster was noticed after the upgrades. The smaller HP bikes will definitely show the gains more than the bigger twins. The time and money spent upgrading brought huge smiles to my wife's face as she cracked on the throttle so it was worth it.

Dynojet Sportster Instructions

Here are the actual instructions from Dynojet for an 05 883XL. Yours should be similar and if you bought the kit you already have them anyways.

1. Remove the vacuum slide from the carb. Remove the stock needle & spacers, noting the order of assembly. Locate the slide lift hole using Fig. A. With drill bit provided (DD #29) enlarge your slide lift hole. Do not drill the needle hole.

2. Install the Dynojet needle on groove #4. Install the Dynojet washers above the e-clip (Fig. A). Install the Dynojet spring (DSP009) in place of the stock spring, making sure spring is aligned properly. With certain engine modifications, you may experience better fuel mileage with the stock slide spring.

3. Remove the stock main jet and remove the emulsion tube (Fig. B). Sometimes referred to as the main jet holder. Replace the stock emulsion tube with the Dynojet emulsion tube provided (DET001). When the Dynojet emulsion tube is fully seated there will still be threads visible. Install the Dynojet main jet provided.
Use the DJ165 main jet with a completely stock bike. Use the DJ170 main jet with aftermarket exhaust or airbox. With an aftermarket exhaust and airbox use the DJ175 main jet. With an aftermarket exhaust, airbox and cam, use the DJ180 main jet. With engine modifications, ie: cam, head work, airbox, and high flow aftermarket exhaust, it may be necessary to use the DJ190 main jet.

4. Locate the fuel mixture plug (Fig. B), if you see a screw head at Fig. B proceed to the adjusting procedure. With the DD #5/32 drill bit provided, carefully drill through the plug. NOTE: The mixture screw is directly underneath this plug, be ready to pull back on the drill the instant you break through. Use the screw provided to secure and remove this plug. Carefully turn mixture screw in until lightly seated, then back out 3 1/2 turns.