I removed the AIS on my '03 today and installed the MaxAir plug kit. I thought while I had it partially apart that I'd go ahead and pull the carb and clean and re-jet it, too cold to ride anyway. When I pulled the tank I found several cracks in the manifold, most of them appear to be superficial, but a couple are pretty deep. I didn't see any evidence of leakage thru them even though it has backfired pretty bad. I did find that the vacuum line from the manifold to the AIS was rotten and cracked, could've been some of the problem, and one side of the reed valve in the AIS was sooted up really bad too. Anyway, the question is, have any of you Roadie owners had this problem? All help, and even a few snide comments are always welcomed.

A test that might help is while running the engine, spray some WD40 on the suspected cracks. If there is a change in speed it would be an indication of a leak. I have seen some posts of cracked intake.

Dave

Thanks Dave. Yeah I did find that one of the cracks was all the way thru. I ordered a new one a few minutes ago, and I'm going to go ahead and clean/re-jet the carb while I've got it off. Santa has evidently been monitoring my web surfing too, (gotta watch that!), "she" asked if I'd like to have a Hypercharger for Christmas! Guess I'd better get that wish list finished, huh?