i hear u about hard to get an accurate torque o the intake bolts pita! You can try the spray test to check for leaks . Good luck with it.

If you google Harley Evo intake install these videos are very helpful.

 

I removed the carb for the 2nd time. Took it apart and recleaned everything. I re-tightened the exhaust manifold bolts. Put it all back together and now I have another set of problems. It is having trouble starting. When it did start it backfired through the exhaust vs the carb although there were a couple of backfires through the carb early on. After a while it would not start at all (battery losing juice). Too much for today, so I'll sit back, do some research (Durham man I did watch those videos, thanks) and cool down before I go back and try again.

 

I would make sure your tank is clean and you dont have rust in it. Also from sitting I would replace the fuel line. If there was ethanol fuel in the bike when it sat that would eat away at the rubber fuel line contaminating the carb jets etc... You can pull the carb and clean it all you want but soon as the fuel flows through a bad fuel line your carb cleaning is all for nothing. Also I would have that carb dipped in one of those ultrasonic cleaners. Gumout and a rebuild kit is not enough. That my 2 cents

 

Had similar issue on my FXR with CV carb. I replaced the both jets and that cured the backfiring (had ethanol residue in jets that I couldn't get cleaned out). I also used 00 steel wool on the needle.

Just too lean due to the jets being partially clogged.

 

Thanks for your input. I did check the flow out of the tank in both normal and reserve. There were no apparent issues. Flow was normal. I will need to investigate where I can get access to an ultrasonic cleaner. I will go ahead and change out the fuel line. It seems like a cheap, simple precaution. I am also going to switch out the plastic fuel flow nozzle to a brass one since I did notice some minor cracking.