Is it possible for the heads to be mounted slightly out of alignment with the intake manifold? Which would make for intake leaks.?

 

no

jugs have alignment dowels to align them to the cases, and dowels to align the heads to them. (and there aint much slop in the head bolts where they pass through the head.

that's why the intake manifold gaskets (seals) are tapered, so they squish down and make a good seal.

you sure you have intake leaks? you use loctite on the bolts? (i made that mistake once, and mine loosened up on me). are the flanges flat/true? (they can warp)

 

Yeah this

 

What bike are you asking about?

 

97 WG. I have had intake leaks in the past and had them reoccur too soon after fixing. The thought just came to mind maybe the heads could be off. The heads were shaved when I built it.
If or when it leaks again, I bought new S&S flanges & S&S seals for the S&S manifold. Stock HD seals are thicker, should I use the thicker HD seals?

 

I did check the flanges last time for being flat.

Are you saying Loctite on the intake bolts? I don't think I did last time but have not noticed them loosening. Can I over tighten intake bolt and cause the leak?

 

Sorry, I can't recall the answer to your question as it pertains to evo's. I do know that Shovels and prior you could "twist" the heads to better align the manifolds.

 

That's exactly why I had the thought.

 

On a twin cam you can't get the heads out of line and even if you decked the heads it doesn't change the interface at all. I would suggest you might be over tightening the bolts.

 

Thanks Span, I was hoping you would chime in.