I have changed every sensor and o ring on the throttle body. I have even changed throttle bodies including the map sensor seal. They are not out of round.

When I take it back off next I am going to try and put it back on with the oem backing plate and without flanges and seals. Then mark the ports with a pencil and see if I am off center when bolted down. I'll update this post then. Anything is worth a shot now

 

By any chance are these different heads than what came off your bike?
There was an intake bolt pattern change between 2003 and 2004 IIRC and if the flanges are from a 2006 and the heads are 2003 there will be an air leak.
Bob

 

thanks for the thought but they are 96" inch heads and my dyna is a 2006 which uses the same flange patter that I am using. I have even tried multiple new flanges

 

So when you spray the manifold does the RPM drop as soon as it hits the right spock on the manifold connection or does it take a few seconds?

 

it's right when I spray the flange at the intake spigot to the flange seal. Not at the head to the seal. And I am spraying from the air cleaner side of the bike and not the horn side.

 

So you are saying that as soon as the spray hits the area between the flange and manifold the motor stumbles. That being the case with the manifold is cracked or when you tighten done the AC backing plate the manifold is shifting. It's hard for air to leak past the round part of the spigot any other way except for an out of round spigot or screwed up flange which has already been brought up.

 

Max just spurred another possible issue. If spacing is not correct, when the a/c backing plate is tightened down it will push on the intake creating a leak.
The test for this is simple, while the engine is idling loosen the 2 breather bolts to relieve the tension on the t/b.
If the idle quality changes and no longer has the leak when sprayed, you found it. Be sure there is no tension on the t/b when tightened by making sure spacing between the backing plate and heads are not doing anything but holding the t/b in position ONLY.
Let s know,
Bob

 

Nothing is cracked. I am a 1000 percent sure of that. I think it's pulling like you guys are saying. I have my oem air cleaner and I will try with that hopefully on Wednesday if I get done with Hurricane prep

 

Because of your thread/troubles here, and my idle being just as crap (tho I can't for the life of me find any leak) ...I went ahead and replaced my intake seals over the weekend.

I have the Harley stage 1 backing plate which has O rings where the plate mounts to the heads with the breather bolts.

Those O rings compress about 1mm and were enough to go from the intake flange bolts spinning in by fingers to needing a wrench on them.

I spaced the O ring mounting bolts (like you did earlier in the thread) and made sure the intake flange bolts were still "neutral" and turnable with fingers, with the breather bolts fully tightened down.

...then tightened them up last. Idle is still crap tho

EDIT ADD: Surely these things can't be THAT fussy, are they??

 

You and I have very similar cams. Are cams the only thing you had done or other stuff too Gordon?

On a serrated note my disassembly will have to wait. Hurricane