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| techtalk:evo:carb03a [2019/08/28 23:42] – [Installing the Intake] hippysmack | techtalk:evo:carb03a [2025/09/03 13:37] (current) – [Installing the Intake] hippysmack |
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| 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. \\ | 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)) ||| | | 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)) ||| |
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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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| | 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)) || | | Both "head" ends of the manifold should be equally spaced to the flanges. ((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|}}| | |{{: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|}}| |
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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. ((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 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. \\ |
| 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. \\ |
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| 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) |
| 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. \\ |
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| | 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)) ||| |
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