Even Flow Intake

Instructions for installation and set-up.
First remove old carburetors and rubber boots. Intake may mount facing left or right.
Carefully position intake and start the bolts. Do not crossthread! Once all four bolts are started, you can tighten them down evenly. Tighten until the intake flange is snug to the head. Do not overtighten! The threaded holes can take up to 70 inch-lbs of torque, that is more than enough. If you have access to an inch-lb torque wrench, I recommend 60-65 in-lbs max. It's important to make sure the flanges bottom out against the heads. I've discontinued the copper shims for now, you can simply spread RTV gasket maker directly on the flanges, or cut out some paper gaskets. I'll be happy to send paper gaskets to anyone who needs them. RTV Application tip, courtesy of Bill G: Apply the RTV in a circle around the flange, .25x.06. (That's 1/4" wide and 1/16" deep). See photo below. Position the intake and start all bolts. Run them down finger tight, or use a wrench if needed, to leave just a slight gap between the flanges and the head. 1/16" or so. Now, let the RTV set for a couple hours to overnight. Come back and tighten everything down. The theory is thus: if you tighten it down on wet rtv, most of it gets squeezed out. If you let it cure, you're tightening onto cured material, and therefore get a better seal. Thanks for the idea, Bill!

In general, I suggest removing all extraneous items such as the AIS and factory air filter.
Mount the carburetor of your choice. The TM40 is a superior choice for best performance. Use a rubber boot bolted to the intake front flange, such as p/n M-VM36-200K.
If your bike has a fuel pump, order a 2.0 needle and seat for the TM40. P/n N149.040.
If you've bought my kit, all these items are included. Route fuel line, throttle cable(s), and don't forget the pressure switch vacuum line if you have an XV1000/1100.
When using a TM40, push-pull throttle cable is necessary.
If you have an older bike with a single throttle cable, you can order a push-pull assembly in my store.

Initial settings for 1000/1100: 165 main jet, three notches down on the needle. Also the big bikes seem to need a #20 pilot jet. That's for pipes with some backpressure. Open pipes require bigger jets. I don't have testing data for smaller engines, so you'll have to experiment some until I get tests done.

If using a BST40: 140-145 main jet, pilot screw closed or ¼ turn open, 1-2 .020 washers under needle. I don't recommend trying to use a Hitachi carburetor. The BST40 will run rich at idle due to excess fuel being drawn up the main jet. I haven't developed a solution for this. Other carburetors may work, but the ones mentioned are the only ones tested. EDIT: The Harley (Keihin) CV40 is a great carburetor, however I have no tuning information on that one.
While this intake will work with factory exhaust, best performance is possible with something less restrictive.