Table of Contents
This is an old revision of the document!
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 Model | Manifold Part# | Material | Throat Dia. | Bolt Hole Dims/Spacing | OEM Carb | 
| 1957-1971 Sportsters | 27021-57 | Cast iron | 1.562“ | .39” holes on a 2.688“ b.c. 1) | Linkert Tillotson | 
| 1972-1974 Sportsters | 27021-71 | Cast iron | 1.562” | .33“ holes on 2.750” b.c. 2) | Bendix / Zenith | 
| 1975-1979 Sportsters | 27021-71A | Aluminum | 1.562“ | .33” holes on a 2.750“ b.c. 3) | Bendix / Zenith Keihin “butterfly” | 
| 1980-1985 Sportster | 27021-78 4) | Aluminum | Keihin “butterfly” | ||
| HD Big Twin Manifold Part Numbers | |||||
| Year Model | Manifold Part# | ||||
| 1971-1975 FL/FLH/FX | 27021-71 5) | ||||
| 1976-E1980 FL/FX | 27021-71A 6) 7) | ||||
| 1975-1979 Sportster Intake Manifold 27021-71A 8) | ||
|  |  |  | 
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. 
| 1980-1985 Sportster Intake Manifold 27021-78 9) | ||
|  |  |  | 
Seals - Intake to Heads
|  | ||
|---|---|---|
| Intake to Head - Hardware History. 10)11) | 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. 16) 
 17)
 17)  18)
 18) 
4) 
1979-1985 HD Sportster Parts Catalog
5) 
HD 1961-1976 ElectraGlide/SuperGlide Parts Catalog pg 19
6) 
HD 1941-1978 ElectraGlide/SuperGlide Parts Catalog pg 17
7) 
HD 1971-1980 FX/SuperGlide Parts Catalog pg 25
8) 
photos courtesy of Ebay seller, animalhouse2010, Link to Ebay store: 
9) 
photos courtesy of Ebay seller, Robison Motorcycles Link to Ebay Store 
10) 
See Brucstoudt & Dr_Dick - XLForum - http://xlforum.net/forums/showthread.php?t=2079889
12) 
, 13) 
, 14) 
, 15) 
photo by The Doctor71 of the XLFORUM http://xlforum.net/forums/showthread.php?t=2071371
16) 
66xlch of the XLFORUM http://xlforum.net/forums/showthread.php?t=1079081&page=5
17) 
photo by 66xlch of the XLFORUM http://xlforum.net/forums/showthread.php?t=1079081&page=5
18) 
photo by DirtyCory of the XLFORUM http://xlforum.net/forums/showthread.php?t=1079081&page=7








