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techtalk:evo:carb03a [2019/04/10 00:22]
hippysmack [Installing the Intake]
techtalk:evo:carb03a [2019/08/28 23:42] (current)
hippysmack [Installing the Intake]
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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 http://​xlforum.net/​forums/​showthread.php?​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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 |Install the intake with the slots toward the left side of the engine. \\ Leave the bolts loose until you install the carb. ((photos by Hippysmack))|| |Install the intake with the slots toward the left side of the engine. \\ Leave the bolts loose until you install the carb. ((photos by Hippysmack))||
 |{{:​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|}}|
 +
 +|  Both '​head'​ ends of the manifold should be equally spaced to the flamges. ((photos by Matt Black of the XLFORUM http://​xlforum.net/​forums/​showthread.php?​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 http://​xlforum.net/​forums/​showthread.php?​t=2011585&​highlight=intake+manifold&​page=2)) \\ 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)) \\