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Sportster Motorcycle Air intake, Carburetor, EFI, Fuel, and Exhaust Problems, advice and/or how tos for Sporster and Buell motorcycle carburators, Electronic Fuel Injection (EFI), Air Intake, Fuel and Exhaust.

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  #91  
Old 8th July 2018
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I think if you look at the flanges the bolt hols are not centered
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  #92  
Old 8th July 2018
Matt Black Matt Black is offline
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You guys are great. I flipped my flanges, mounted the carb like before, tightened the flange bolts just enough to hold the manifold in place and then removed the carb and finished torqing the flanges.

Before:
20180706_202357 by David Arens, on Flickr

After:
20180708_111226 by David Arens, on Flickr

This probably also explains why when I removed the carb for the first time to rebuild it, I found I could wiggle the manifold about 1/8" up and down even though the bolts were tight. I guess it could have been why the original seals were trashed as well.

I'm waiting on a couple more things to come in (1/4" spring type hose clamps from Amazon and a custom length throttle cable from Barnett) and then I can continue to put things back together.


Thanks again.
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  #93  
Old 8th July 2018
Matt Black Matt Black is offline
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Just to complete the carb mods/repairs part of this thread, I followed the instructions on the CVP website to remove the old fuel elbow fitting. You basically break off the remaining plastic which exposes the inner brass tube. You use a 1/4-20 tap to thread the hole and then make a little puller with a 3-4in 1/4-20 bolt and a deep socket. Once I mocked everything up with the carb on the bike to get the new elbow clocked correctly I pressed it in using my bench vise. The whole operation was pretty straightforward and simple.

I should have mocked everything up better before pressing in the elbow, the angle I thought I would need ended up pointing too far forward and the Lowbrow/Gasbox carb support bracket blocked the fuel line. I had to gently twist the elbow counterclockwise from about 1 o'clock back to about 11 o'clock.

It did take some tweaking the length and routing of the line and the angles of the inlet elbow and the petcock outlet to get the fuel line to where it didn't rub anywhere.

I was also limited in where I could clock the petcock by the position of the selector lever interfering with the throttle cable. This won't be an issue if you use a different style petcock or your petcock is on the left side.



20180607_213024 by David Arens, on Flickr

20180706_195444 by David Arens, on Flickr
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  #94  
Old 9th July 2018
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Glad to see you are making progress man. As far as the tooling, I cut the end off a standard Allen wrench like IXL2Relax suggested. Works great!

XLF is the best Bro! Keep plugging, but keep us updated!

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  #95  
Old 9th July 2018
Matt Black Matt Black is offline
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I cut one down too but I guess I didn't cut it down enough. It works great on the left side but it's still too big to get in when the carb is on.

Thanks! Progress is slow but sure. Coming up on one year since I bought the bike later this month. I've done a lot but there's still a ways to go. Tires and exhaust are going to be the remaining big ticket items, but there's a bunch of smaller stuff too. I'd also like to swap wheels to wire spokes, or at least get a mag for the rear instead of a solid but that's a want, not a need.

I was shooting for late summer / early fall but it doesn't look like I'm going to make it.
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