- Get your two left side bolts ready and then **gently** start pulling up on the hammer handle until at least one of them is aligned. When one is aligned screw it as far as you can get it in by hand. The other bolt is liable to take considerable pressure on the hammer handle to get it to line up but it can be done! The manifold is VERY durable and will not break. If you’ve got a three-foot long sledgehammer handle in there and can’t get it lined up, something isn’t right – back off and start again. An extra pair of hands comes in real handy now. This is what the left side will end up looking like:
- At this point you are all set. Tighten all bolts evenly in a round about fashion and you are done with this part!
Now for the Airbox Mount
Once you’ve gotten the carburetor mounted and your hoses/cables all hooked back up and are 100% sure you’ve got the carb fully seated to the boot and the boot seated and clamped to the manifold you’re going to notice that the carb sticks out a little further (about 5/8” overall) and the stock airbox doesn’t want to fit. Here’s the easy cure for that!
You’ll need surprisingly few parts to make this a professional, neat looking installation and I have done the homework for you. I had to improvise on the parts I used in order to do the install the first time but have a list of the correct parts so you don’t have to mess with them. This makes for a “bolt-on” installation. Here are the parts you need and where you can get them from:
Parts Needed for install
20083 ---- 1/4 X 7/16 X 5/8 SPACER CHROME (2 each needed)
20094 --- 1/4 X 7/16 X 7/8 SPACER CHROME (1 each needed)
12744 --- 6 X 45 ALLEN SCREW CHROME (3 needed)
12745 --- 6 X 50 ALLEN SCREW CHROME ( 1 just in case needed…)
23987 --- M6 FLATWASHER CHROME (3 needed --- optional)
10110 Six Mile Road
Northville, Michigan 48167 USA
Phone (248) 305-5100
Fax (248) 305-5110
Call us toll-free at 1-800-897-5025
Since the manifold shoves the carburetor out approximately 5/8” you’ll need to move the airbox out that far also. What I did was get the above 5/8” spacers from Gardner above and use them. One of them I had to cut down to add to another spacer to get the 7/8” spacer I needed. I simply cut it apart and super-glued it together. Instead of fumbling around with the bolts and spacers driving me nuts falling all over I super glued them to the airbox itself before installation too (stock airboxes are a dime a dozen on ebay or the forum…get a spare and keep your original). Here’s a good shot of what it looks like.
Here’s how I made the 7/8” spacer by cutting and gluing a piece onto one of the 5/8” spacers:
Here’s the airbox with two spacers in place --- NOTE the long (7/8” spacer) is the Top Rear spacer:
The airbox itself can now be bolted on and will make for a nice clean install and will look like it was made to be there! I’ll include some shots so you can see it really doesn’t stick out that far (Try a Kury TV if want one really hanging in the breeze….). Here is box mounted:
You can see here the rear spacer is just a tad longer than the front but everything lines up just perfect! Here is manifold, airbox, and filter installed on bike and running. As you can see, it really is a comfortable fit:
What the Nemesis manifold is going to do for you is give you a MUCH improved idle quality, smoother power delivery throughout the power band and will add some ponies too. So twist it up and go Fat Boy hunting!
Be sure you REMOVE the head stay from the left hand side of engine (the part that bolts to the frame and then to each cylinder head) This will make install much easier.
Ride Safe and Ride what you like!
©Arthur K. Armfield 2003
Free for personal use and for ALL members of the Road Star Riders Forum and Readers of The Road Star Clinic web page.
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Quote this article on your site | Views: 22731
|Written by texstar58, on 03-15-2011 10:59 |
I was a little worried about changing the manifold and installing a Nemesis. However, I got it and pulled the carb, the left side support frame for the fuel pump. With the O-rings in place I put this thing on in 45 minutes. Piece a Cake!! It took me two and a half hours to install an after market airbox....LOL
I'm sure glad I found this article and this site!!!
|Email for Nemesis from DK Powder Coat|
Written by Rayjay, on 12-22-2008 20:45
Email email@example.com for a Nemesis Manifold. DK Powder Coat is the company. I ordered the manifold and valve springs from him and will order the Nemesis coils in the future. Good guy to buy from.
Written by been71lk8, on 12-20-2008 22:19
i,m looking for this manifold to buy.i,ve been looking for ever .can you send there web site.thanks
|Spacer for BAK|
Written by Rayjay, on 10-01-2008 13:46
I have a Baron's Big Air Kit with K&N filter. When I installed the Nemesis, the carb stuck out about 1 3/8" more, was tilted slightly upwards and 3/8" lower. I used scrap 1/2" chrome plated brass tubing for spacers. I got stainless bolts locally ( one 6mm x 1.00 x 2 1/2" and one 6mm x 1.00 x 2" long). I used the original screw for the bottom since that fit OK. I had to alter the back of the box by moving the arms up about 3/8". Drilled holes and used self-tapping screws after I tapped the holes. Had to shim the bottom of the arms with sheet metal due to the slots for original arm positions. Put locktite on inside of box for new arm screws, positioned box and screwed front cover on with filter. Probably could have used bolts with self-locking nuts inside the box. Solid install, just going to be a little trouble removing. Make sure filter is clean before re-installing!
Written by Rayjay, on 09-24-2008 18:51
I installed the Nemesis 9/24/09 and it went in very easily. I first did some grinding of interior casting snots.
I had called DK (seller) and he said that the small clear silicone pack was to put a few dabs under the *O* rings to hold them in place (I did 4 spots) and some of the rest should be lightly smeared over the head flange areas to allow the manifold to slide on easily (1/6th thick).
BEFORE you silicone things, try them for fit and make adjustments (grinding) if necessary. Mine went on without a hitch.
Now I have to get longer screws and make spacers for my BAK. Will report on that when done.
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