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techtalk:evo:carb03a [2019/04/09 20:38] hippysmack [Installing the Intake] |
techtalk:evo:carb03a [2024/01/02 22:15] (current) hippysmack |
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| ====== Installing Intake Manifold (27004-88A) ====== | ====== Installing Intake Manifold (27004-88A) ====== | ||
| |{{:techtalk:evo:carb:intake_manifold_3_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:carb:intake_manifold_3_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| + | ===== Repairs ===== | ||
| + | If the bike is dropped on the air cleaner (right side), sometimes that will bend the intake manifold at the carb mouth. \\ | ||
| + | If the bend on the manifold makes the inlet out-of-round, remove the manifold and either repair (if possible) or replace it. \\ | ||
| + | You can try to heat up the bent area and very carefully tap the edges to get them back into round. \\ | ||
| + | Be careful, the manifold material will crack. \\ | ||
| + | You could also try to place the inlet on top of a small piece of 2x4 before tapping on it with a nylon tipped hammer. \\ | ||
| + | Or use a short piece of wood, curved front, as a drift so you're not applying excess pressure in one spot. \\ | ||
| + | You can try using some JB-Weld to reform cracked or missing pieces and smooth out the seam with sandpaper. \\ | ||
| + | The rubber carb seal should go over the mouth of the manifold completely but you want it to be close to the proper curve or the rubber will not flex enough to seal properly. \\ | ||
| + | If you have any doubts about your ability to tap out a flat spot then just let it alone and see if the rubber can make the seal. \\ | ||
| + | |||
| + | Be sure to read that Carb page in the Sportsterpedia about mounting the carb. \\ | ||
| + | If you pre-align the carb, make sure the mounting bracket is adjusted in the right place. \\ | ||
| + | Use the right spacers for the bracket so the carb just butts against the bracket, you will be a long way toward eliminating those pesky intake leaks. \\ | ||
| + | |||
| + | You can also try putting a 34mm socket in the hole and gently tap the socket with a hammer to try and straighten and out of round crab inlet. \\ | ||
| + | | Repair on 'out of round' intake manifold. ((photos by Matt Black of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page8?t=2068828&page=8)) ||| | ||
| + | |{{:techtalk:evo:carb:bent_intake_manifold_fix_1_by_matt_black.jpg?direct&300|}}|{{:techtalk:evo:carb:bent_intake_manifold_fix_2_by_matt_black.jpg?direct&300|}}|{{:techtalk:evo:carb:bent_intake_manifold_fix_3_by_matt_black.jpg?direct&300|}}| | ||
| ===== Considerations ===== | ===== Considerations ===== | ||
| + | |||
| **Intake Mounting Bolts**: \\ | **Intake Mounting Bolts**: \\ | ||
| Inspect the intake mounting bolts for distortion at the threads as well as the Allen socket in the head. \\ | Inspect the intake mounting bolts for distortion at the threads as well as the Allen socket in the head. \\ | ||
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| The flanges are directional. There is a letter stamped on each flange for (F) - front or (R) - rear placement. \\ | 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. \\ | 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 ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) or otherwise toward the left side of the bike. \\ | + | The slot goes toward the 'tight side' between the cylinders ((IXL2Relax of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page9?t=2068828&highlight=intake+manifold&page=9)) or otherwise toward the left side of the bike. \\ |
| - | If you look at the flanges it should cause a bad mis-alignment if you use them the other way. ((rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\ | + | If you look at the flanges it should cause a bad mis-alignment if you use them the other way. ((rocketmangb of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page9?t=2068828&highlight=intake+manifold&page=9)) \\ |
| |{{:techtalk:evo:carb:intake_manifold_flanges_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_flanges_1_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:carb:intake_manifold_flanges_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_flanges_1_by_hippysmack.jpg?direct&300|}}| | ||
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| ====== Installing the Intake ====== | ====== Installing the Intake ====== | ||
| Although this can be done with the fuel tank on, it's easier if you remove it. \\ | Although this can be done with the fuel tank on, it's easier if you remove it. \\ | ||
| - | The idea is to align the manifold & the carb BEFORE tightening everything into their final positions. ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\ | + | The idea is to align the manifold & the carb BEFORE tightening everything into their final positions. ((IXL2Relax of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page9?t=2068828&highlight=intake+manifold&page=9)) \\ |
| This will help to prevent air leaks. \\ | This will help to prevent air leaks. \\ | ||
| Normally, the slotted holes of the manifold flanges go in the tight side & the round holes go outward. \\ | Normally, the slotted holes of the manifold flanges go in the tight side & the round holes go outward. \\ | ||
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| |{{:techtalk:evo:carb:intake_manifold_13_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_14_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:carb:intake_manifold_13_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_14_by_hippysmack.jpg?direct&300|}}| | ||
| - | Having the carb in place allows the carb seal and the manifold to squarely mate with the carb before tightening the intake bolts. ((John Harper of the XLFORUM http://xlforum.net/forums/showthread.php?t=2011585&highlight=intake+manifold&page=2)) \\ | + | | Both 'head' ends of the manifold should be equally spaced to the flamges. ((photos by Matt Black of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page10?t=2068828&page=10)) || |
| + | |{{:techtalk:evo:carb:intake_manifold_flange_alignment_1_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_manifold_flange_alignment_2_by_matt_black.jpg?direct&200|}}| | ||
| + | |||
| + | Having the carb in place allows the carb seal and the manifold to squarely mate with the carb before tightening the intake bolts. ((John Harper of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/188935-intake-seals/page2?t=2011585&highlight=intake+manifold&page=2)) \\ | ||
| 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 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. \\ | The carb's vertical position will change during installation. \\ | ||
| Line 50: | Line 73: | ||
| They they will be pulled away from there mating surfaces while following the rotating carb position. \\ | They they will be pulled away from there mating surfaces while following the rotating carb position. \\ | ||
| - | To align the carb to the intake, you can temporarily mount the carb: ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\ | + | To align the carb to the intake, you can temporarily mount the carb: ((IXL2Relax of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page9?t=2068828&highlight=intake+manifold&page=9)) \\ |
| * Remove the rubber seal at the manifold mouth. | * Remove the rubber seal at the manifold mouth. | ||
| * Put the carb (on it's bracket) in place (bracket bolted to the heads). \\ (to see if the carb aligns properly with the manifold intake opening) | * Put the carb (on it's bracket) in place (bracket bolted to the heads). \\ (to see if the carb aligns properly with the manifold intake opening) | ||
| Line 64: | Line 87: | ||
| * Install the carb in the intake, the air cleaner on the carb and install the carb support on the heads loosely. | * Install the carb in the intake, the air cleaner on the carb and install the carb support on the heads loosely. | ||
| * Then wiggle the intake up/down and visually inspect the seal top to bottom for evenness. | * Then wiggle the intake up/down and visually inspect the seal top to bottom for evenness. | ||
| - | * Torque the crab support bolts. | + | * Torque the carb support bolts. |
| * Then torque the intake bolts. | * Then torque the intake bolts. | ||
| * Recheck the seal for evenness. | * Recheck the seal for evenness. | ||
| Line 83: | Line 106: | ||
| Do not over-torque the intake bolts. This will probably cause a leak. \\ | Do not over-torque the intake bolts. This will probably cause a leak. \\ | ||
| - | | Example of seals with over-torqued bolts. ((photos by Matt Black of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=8)) ||| | + | | Example of seals with over-torqued bolts. ((photos by Matt Black of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-intake-and-exhaust/sportster-motorcycle-air-intake-carburetor-efi-fuel-and-exhaust/193103-newbie-cv-rebuild/page8?t=2068828&highlight=intake+manifold&page=8)) ||| |
| |{{:techtalk:evo:carb:intake_bolts_too_tight_1_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_2_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_3_by_matt_black.jpg?direct&200|}}| | |{{:techtalk:evo:carb:intake_bolts_too_tight_1_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_2_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_3_by_matt_black.jpg?direct&200|}}| | ||
