REF: Carburetor, Intake Manifold & Exhaust

Ironhead - Installing a Keihin CV Carb

See also in the Evo section of the Sportsterpedia:

The filter sticks out about 1“ farther than before, but it doesn't look bad.
The bike now runs pretty decently with a stable idle. There is a lot more mid-range punch. It's weak on the top end, though.
Here's a view from the rider's seat. 1)

Remove the old air cleaner and carb.
2) 3)

Intake Manifold to Carb Mount

Three most common ways to mount a CV to an Ironhead intake:
A Mikuni metric adapter, a press on adapter or a non press adapter - (requires stock CV seal). 4)
A press-on adapter is sold that press-fits on the carb spigot with JB Weld.

5) 6)

Carb to Air Cleaner Mount

The original XLCR intake manifold was used but with a rubberized flanged adapter to the carb.
A Screaming Eagle / K&N air filter assembly was used for this carb swap. Here are some pics of mounting it to the carb.
7) 8)

The air cleaner element was installed, connected up the fuel line, and throttle cable.
(the return cable is not being used here because the pull spring is pretty stiff. If it were to stick, it can hit the kill button)
9) 10) \\ 11)

Installing the VOES (if applicable)

This is not necessary, but here the VOES was attached to the new filter back plate.
12) 13)

Bolt up the carb using the rubberized flange adapter.
The VOES wiring reconnected. (one wire to ground, the other to the ignition (MSD) control unit for vacuum ignition retard).
An aluminum brace was fabricated to support the carb.
14) 15) \\ 16)

Leg Room

These pics show the stock air filter protrusion from the gas tank.
17) 18)

Pics of Conversions

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