Table of Contents
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EVO: Carburetor, Intake Manifold & Exhaust - Sub-03A
Installing Intake Manifold (27004-88A)
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Considerations
Intake Mounting Bolts:
Inspect the intake mounting bolts for distortion at the threads as well as the Allen socket in the head.
Previous over-tightening or misaligned wrenches can ruin these bolt's ability to be retightened properly.
You can replace the bolts with grade 8 or stainless ones from a hardware store.
There is only 6-10 ft-lbs on these bolts so shear strength is not an issue.
Also consider replacing the rear / slotted end bolts with hex bolts instead.
This will make these easier to work with during installation of the intake.
There is not enough room on the carb side holes for a hex bolt due to the small clearance between the intake body and hole.
| Stock mounting bolts replaced with stainless, rear bolts changed to hex head. 1) | |
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Flanges:
Double check flange placement before tightening them.
The flanges are directional. There is a letter stamped on each flange for (F) - front or (R) - rear placement.
There is a mounting hole on one side and a mounting slot on the other.
The slot goes toward the 'tight side' between the cylinders or otherwise toward the left side of the bike.
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Installing the Seals
| Put the flanges on the intake. Double check front / rear flange placement. 2) | Install the intake seals with the chamfered side toward the flange. 3) |
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| The carb seal goes on the intake port. Check that the seal is fully seated when installed. 4) | |
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Installing the Intake
| Install the intake with the slots toward the left side of the engine. Leave the bolts loose until you install the carb. 5) |
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Having the carb in place allows the carb seal and the manifold to squarely mate with the carb before tightening the intake bolts. 6)
The carb can also be installed in the intake (without support) in the wrong vertical position to mate with the bolts in the head.
The carb's vertical position will change during installation.
If the intake is tightened before the carb support is installed to the carb and heads, it will stress the intake to head seals.
They they will be pulled away from there mating surfaces while following the rotating carb position.
| Install the carb and carb support. (air cleaner backing plate) 7) | Getting to the carb side bolts isn't easy from this point of view. 8) |
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| If you remove the top left motor mount, you'll have easier access to the intake bolts. 9) | Then you can get both hands in there to install the wrench with several pulling options on the bolts. 10) |
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