James Gasket Carb Carburetor-to-Intake Manifold Seal Kit 40mm JGI-27002-89-K for Harley Models, see fit chart

OVERVIEW

This direct-replacement carburetor-to-intake manifold seal kit restores a vacuum-tight connection between the carburetor and engine intake ports, eliminating unmetered air leaks that typically cause rough idling and lean misfires. Designed specifically for Harley-Davidson models equipped with 40mm intake manifolds, the set includes resilient, reinforced rubber composite gaskets engineered to withstand thermal cycling and modern fuel chemistries. It provides a complete OEM-style rebuild solution for Sportster, Dyna, Softail, and Touring platforms requiring 40mm intake service.

ENGINEERING & PERFORMANCE

Precision-cut seal profiles maintain consistent airflow and fuel metering at the carburetor mounting flange, preventing pressure drops that degrade throttle response. The three-piece layout covers every critical intake junction—including one carb-to-manifold seal and two intake-to-head seals—providing comprehensive protection rather than a partial patch. Constructed from reinforced rubber composites, the gaskets resist chemical breakdown from ethanol-blended fuels and remain dimensionally stable under intense heat. Integrated reinforcement layers block the vibration-induced stress that commonly leads to micro-cracking and failure in aging factory components.

KEY FEATURES

• Includes one carburetor-to-intake manifold seal and two intake-to-cylinder head seals
• Reinforced rubber composite construction resists ethanol fuel exposure and extreme heat
• Precision profile geometry ensures leak-free, OEM-specification alignment
• Eradicates unmetered air leaks that compromise idle quality and engine smoothness
• Targets 40mm intake port applications across multiple Harley-Davidson families
• Durable design blocks vibration cracking common in older stock rubber
• Part number JGI-27002-89-K for accurate system cross-referencing

TECHNICAL SPECIFICATIONS

• Brand: James Gasket (JG)
• Part Name: Carburetor-to-Intake Manifold Seal Kit
• Part Type: Gasket / Seal Kit
• Material: Reinforced Rubber Composite
• Supported Years: 1989–2009
• Compatible Trims: Sportster, Dyna, Softail, Touring

FITMENT

• Harley Sportster (1989–2009)
• Harley Dyna (2000–2009)
• Harley Softael and FXR (1989–2009)
• Harley Touring (1989–2009)

WHY HARLEY RIDERS CHOOSE THIS

Riders choose this rebuild set to solve chronic idle surges and cold-start hesitation caused by deteriorated intake sealing. By replacing both the carburetor surface and the cylinder head junctions, the kit prevents vacuum leaks that starve the carburetor of the proper pressure needed for accurate fuel metering. The reinforced rubber compounds maintain their structural integrity under heavy vibration, ensuring jetting calibration stays consistent over time. This precise, multi-piece kit allows riders to restore smooth power delivery and reliability efficiently without the cost of replacing entire manifolds.