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Try to get the flanges torqued down evenly, and keep the spigot centered while your doing it. I found that I couldn't cleanly get at the left side Allen bolts with a torque wrench so I replaced them with hex heads. Then I could use a crow's foot on that side. The Allan's on the right side are easier to get at.
Hope that's helpful.
On my phone and for some reason I can't read your whole reply. Will get it when I get home.
I'm so glad I found this thread. I have an '06 883 50K on it. It started doing this coughing/spitting thing in February. I thought maybe too long on the enrichener fouled the plugs. Plugs looked fine, but replaced them anyway since it was a cheap fix. Unfortunately, it's still coughing/spitting. Does anyone know of a good read/video to learn how to check/fix an intake leak? I've learned to do most of my work myself and would appreciate any advice.
Before you disassemble to replace the seals spray them down with carb cleaner while the bike is running to check and see if they are leaking.
You will be able to hear the rpms change if it sucking the carb cleaner in.
Changing the seals isnt a bad job but I try and avoid dealing with those p.i.t.a. Allen bolts that hold the intake on if I can!
^^ Good, but, not with Carb Cleaner...It is good Paint remover, and is too volatile to be spraying in that area...Brake parts cleaner, WD-40, even water...anything will cause a Change if Sucked thru a leak!!!
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