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Buell Forum » XBoard » Buell XBoard Archives » Archive through December 01, 2004 » XB Intake Manifold Seal Leak « Previous Next »

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Keith
Posted on Wednesday, November 17, 2004 - 02:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My 2003 XB9S has developed an intake leak where the manifold bolts to the rear cylinder head. I got suspicious when tooling along in traffic in second or third gear caused the engine to sputter but hard application of throttle caused it to smooth out.

I used the shop manual and some contact cleaner to locate the leak. Spraying it around the read cylinder head/intake manifold connection caused an increase in engine RPM.

Now for my question: I've changed these seals on Harleys before and it is a relatively easy job. However, access to the manifold on the XB is limited.

The shop manual says to nearly strip the bike so that the engine can be rotated on the rear mount to gain access to the intake/fuel injection system. Is there enough room using the correct tools to remove the intake manifold bolts, lift the manifold/fuel injection assembly up only enough to remove the old seals and install the new ones without having to do all that the manual says? Has anyone done this?

Thanks,
Keith
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M1combat
Posted on Wednesday, November 17, 2004 - 02:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hmmm, I haven't dont that but I did remove the entire airbox cover this weekend to take a look at all the cool parts under it... It seems to me that there was enough room to remove the manifold and TB from the top...
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Fullpower
Posted on Wednesday, November 17, 2004 - 08:05 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

recommended procedure: remove motorcycle from intake manifold, replace seals, re-install motorcycle.
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Easyflier
Posted on Wednesday, November 17, 2004 - 08:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'm in the process of rotating my motor now and I don't think you can get at the intake manifold bolts with motor in the frame. Might be able to get a wrench on a couple but don't think you can get them all.

Any Buell techs in here that do this stuff on a regular basis? They could tell us for sure.
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Bud
Posted on Thursday, November 18, 2004 - 12:49 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

i have seen it being done with out the engine rotating.

but you need allot off special tools
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Easyflier
Posted on Thursday, November 18, 2004 - 06:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'd like to see it done, and know what tools they use.

I was going to attempt it on my bike but the head needs to be repaired or replaced anyway so I had no choice but to rotate it.
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Bud
Posted on Thursday, November 18, 2004 - 01:33 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I'd like to see it done, and know what tools they use

he has the ( well almost ; ) )complete snap-on collection

swiveljoints, short hex drives long hex drives,
a broken wrist will help as well

gr,b}
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Easyflier
Posted on Thursday, November 18, 2004 - 06:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

"a broken wrist will help as well "

I'll just rotate the motor down. : )
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Ingemar
Posted on Friday, November 19, 2004 - 06:27 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

http://www.badweatherbikers.com/cgibin/discus/show.cgi?tpc=32777&post=230530#POS T230530
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Glitch
Posted on Friday, November 19, 2004 - 10:40 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ingemar, why the link on how to remove the fan?
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Ingemar
Posted on Friday, November 19, 2004 - 10:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)



Dunno ...

I really don't know ...

And I can't remember why I even posted it ....

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Keith
Posted on Friday, November 19, 2004 - 01:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bud or anyone,

Can you tell me what is needed to replace the seals without rotating the motor? Or in the end, is it easier to just rotate the motor? Help!

Keith
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Darthane


Posted on Friday, November 19, 2004 - 02:06 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just look at it as a bonding experience!
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Bud
Posted on Friday, November 19, 2004 - 04:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Keith,
i never did it my self, i have seen it been done,
and was pleasently surpriced that the actialy could don it like that,
it is still a hell off a job,
but i think iff you take off the ing + mount and right airduct ( to get to the manifold from below ) you should be able to make some space

some little 1/2" sockets with ball joints, and a "force" hex key ( like a normal hex with the ends bend ) will help

but speaking off engine rotating, last time i had the complete engine out in under 3 hours ; )
im not bragging, i hated it every minute off it
with a very serious knock en metal bit's in the oil : (

witch ever way you choose, be ready to do it bouth way's, you'll never be disapointed

good luck ,
bud
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Bud
Posted on Friday, November 19, 2004 - 04:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Just look at it as a bonding experience!

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