How to Replace Harley-Davidson Intake Gasket

Written by christina teter
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How to Replace Harley-Davidson Intake Gasket
You must replace the intake gasket when air begins flowing to the cylinder heads. (motorcycle image by Bionic Media from

The intake gasket on a Harley-Davidson motorcycle keeps air from entering the motorcycle's cylinders. It is located between the intake manifold and the cylinder heads. The gasket requires replacement once the motorcycle backfires or if the motorcycle doesn't sound like the motor is working properly. This procedure requires some knowledge of the inner workings of a Harley-Davidson. You must also remove the air cleaner cover and backplate before removing and replacing the intake gasket.

Skill level:

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Things you need

  • Standard screwdriver set
  • Torque wrench

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  1. 1

    Disconnect the carburettor from the manifold. To do this, turn the fuel system to "Off" with your hand. Once you stop the fuel supply, disconnect the fuel line from the carburettor. Detach the fuel enrichener knob from the bracket -- located above the horn. Also disconnect the throttle and idle cables from the carburettor -- unscrewing them by hand. Pull the vacuum hose away from the carburettor thus releasing the carburettor from the manifold and seal ring.

  2. 2

    Remove the manifold from the cylinder head. Do this by removing the 10 screws that hold the manifold in place with a standard screwdriver and the manifold flange from the two connectors on the manifold. Detach the Manifold Absolute Pressure (MAP) sensor connector from the wiring harness.

  3. 3

    Replace the intake gasket -- located between the manifold and cylinder heads. Once you place the gasket in place, seal it with the manifold flanges and manifold. Ensure you tighten the 10 screws that hold the manifold in place by hand. Reinstall the seal ring on the portion of the manifold that connects to the carburettor.

  4. 4

    Reinstall all parts removed from the carburettor including the throttle and idle cables, air cleaner backplate and the MAP sensor connector. Also, tighten the manifold screws to 8 to 12 foot-pounds with a torque wrench. Reinstall the air cleaner filter and cover as well as the enrichener.

Tips and warnings

  • Keep your work area clean so as not to allow any foreign objects into the carburettor.
  • Do not smoke when performing work on a carburettor.

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