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IH: Carburetor, Intake Manifold & Exhaust

See also Installation of Top End for proper alignment of intake manifold.


Intake Manifold

HD Sportster Manifold Part Numbers
Year ModelManifold Part#MaterialThroat Dia.Bolt Hole
Dims/Spacing
1957-1971 Sportsters27021-57Cast iron1.562“.39” holes on a 2.688“ b.c. 1)
1972-1974 Sportsters27021-71Cast iron1.562”.33“ holes on 2.750” b.c. 2)
1975-1979 Sportsters27021-71AAluminum1.562“.33” holes on a 2.750“ b.c. 3)
1980-1985 Sportster27021-78 4)Aluminum
HD Big Twin Manifold Part Numbers
Year ModelManifold Part#
1971-1975 FL/FLH/FX27021-71
1976-E1980 FX27021-71A

Click Here to go to the TSB page in the Sportsterpedia and download TSB M-788 regarding the changes for the 27021-78 manifold.
In March, 1980, several modifications were made to heads/intake manifolds/clamps used on L1980 1200/1340cc FL/FX models to improve sealing capabilities.

1975-1979 Sportster Intake Manifold 27021-71A 5)
1980-1985 Sportster Intake Manifold 27021-78 6)

Seals - Intake to Heads

Intake to Head - Hardware History. 7)8) OEM Part Numbers
1957-78 Used exact same port sealing machining, heads and manifolds Uses O-rings - 27060-55 - Clamp 27063-57.
1979 Confusing because it had the o-ring machining but used rubber bands Uses rubber bands - 27062-78 - Clamp 27063-78.
1980-later Made with “o-ring delete” machining. Uses rubber bands - 27062-78 - Clamp 27063-78.
1979 models could retro fit 78-earlier interface mechanisms as a bolt on mod.
1980-later models needed the heads to be machined for reverting to the straight up o-ring seals.

Bendix

Keihin Butterfly

These V-twin clamps (35-0419) work well for stopping intake leaks. The tool to install them is the same as any oiteker clamp pliers. 13)
14) 15)

4)
1979-1985 HD Sportster Parts Catalog
5)
photos courtesy of Ebay seller, animalhouse2010, Link to Ebay store:
6)
photos courtesy of Ebay seller, Robison Motorcycles Link to Ebay Store
7)
See Brucstoudt & Dr_Dick - XLForum - http://xlforum.net/forums/showthread.php?t=2079889
9) , 10) , 11) , 12)
photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071371
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