| Author | Message | ||
     Red_chili |
We are buying my son's XB9S (he is in a fit of madness, something to do with marriage or something) for my wife. I was tuning it, fattening the mixture/ changing the timing curve, that sort of thing. Made a very nice difference. But after a couple runs, it started idling really strangely. A squirt of carb cleaner on the intake manifold revealed the dreaded failing intake seal. Wow. What a friggin' PAIN in the BUTT to change the intake seals. Wish those James o-rings had come in; I don't want to have to repeat this any time soon. Anybody got some cool tricks to get to the allen bolts cleanly? I ended up getting every flex device known to humankind and found the real show stopper is there is NO clearance for a 1/4" drive allen. And you CANNOT get a regular allen in there, ball end or not, for more than about a 20* turn or so which is not enough to engage the next flat. Maybe a really stubby ball-end allen would fit, but fresh out of those. I ended up cutting the ball end off an allen (RIP ) and using a 1/4" drive socket. Worked OK, but the ball end and another universal flex kinda made things double-jointed. Retorquing is going to be interesting. Might have to use the German method invented by Makit Gutentite. Just looking at it, it seems like the rubber seals are intended to allow a bit of slippage of the intake manifold as the cylinders get hot and 'grow' apart. Maybe that is what is so hard on the seals? I did notice the light mark from the O-rings kinda disappeared at one place on the rear intake manifold machined surface. Possibly the leak area? Does anybody do anything 'extra' not covered in the service manual? | ||
| Texas_firebolt |
havent had the pleasure of changing my intake seals on my xb yet, but i am a harley tech so i would assume that this tool would work as good as it does on the rest of the harleys i work on. and i own one of these babys and it is an awesome tool. theys are specifically made for harley intake manifold bolts and you cant see it to well but it has a stubby ball allen. matco sells it for about $48.00 or you could possibly find one through drag specialties or another catolog for a little cheaper  | ||
| Red_chili |
Looks cool. The problem with XBs is the frame, you can't GET to the allens very easily. So you need a long and somewhat flexible alternative. Thanks for that, though; Scotts makes a trail ratchet 1/4" drive for dirt bikes' tool kits that is also good for tight clearances. Pretty strong (not the quality of the Matco of course) and pretty darn small. By the way I am warming up the XB9 right now, just went into closed loop at idle and no more shenanigans with the intake leak. For tonight!  | ||
| Texas_firebolt |
please post pics of the tool. as a mechanic by trade my inherit weakness is im always looking for that new neat little tool that none of the other guys have. lol. good luck, and keep us informed as to the easiest way as im sure sooner or later ill have to change mine. (those intake seals are one of the biggest weak points in HD's engines. you would think that after 22yrs of the same intake and the same intake leaks that they would come up with something better) sorry, a little ranting going on here. | ||
| Red_chili |
A justified rant. I understand from another Badwebber that Genuine James blue silicone O-rings are what the doctor ordered. I have some on order but the wife wanted to ride yesterday, so there you have it. The tool I used was just a cut down ball end 1/4" allen, driven by a 1/4" socket. Nuttin' fancy. I know all about the tool fetish.  The small ratchet is now made by MSR. Here is a pic: http://www.rockymountainatv.com/viewLargerImage.do ?stockId=98564&navType=type#OtherImages Won't break the bank: http://www.rockymountainatv.com/productDetail.do?navType=type&webTypeId=140&navTitle=Tools%2FShop&webCatId=22&prodFamilyId=11624 (Message edited by Red_Chili on September 02, 2008) | ||
| Aptbldr |
'04 XB12, approx 7500 miles; leakage at intake manifold when engine's fully warm, 'hot'. Pre-repair, diy, what do I want to have on hand? Use OEM replacement seals? More on James seals in posts above? R&R seals at injectors, regardless? Other maintenance tips "while I'm there"? | ||
| Fahren |
Yeah, what ^^^ he said. | ||
| Petebueller |
Texas Firebolt I'd love to find a tool that worked easily with a ratchet like that, but I think the head is too big and the handle too long. There are recesses in the throttle-body to fit the key. You can see them beside the injectors in the picture below.  You can't fit anything with a bigger head anywhere around there. Even the ball socket just fits on and you need to try to push it in and straight with one hand while turning with the other to avoid rounding it. Full credit to Buell - it can be done - but they aren't a screw that goes with impatience. 08 and then 09-10 heads replaced the screw with bolts to match the other side. These are much easier to work on. | ||
| Texas_firebolt |
THis is essentially the same as the harley intakes except it is downdraft. I have used the same 90 degree ball allen wrench you are referring to on harley intakes and the tool i mentioned above is far better than that. I changed a set of XB intake rubbers awhile back and used the matco tool, as well as the little allen wrench, i do believe. It is a tight spot to get into and you just arent going to find a miracle tool but the matco is the best ive seen to date. The biggest limiter on the buells is room as there isnt much to play with since the frame is in the way as well as the heads, etc... | ||
| Petebueller |
It looks good. I'll have to try one out. | ||
| Pkman |
Does the engine have to be rotated to replace the intake seals? If not are the screws accessible from the top when the airbox base is removed? | ||
| Petebueller |
It is touch and go as to whether it is easier all up with an engine rotation. I wrote up my experience here http://www.badweatherbikers.com/buell/messages/384 2/640277.html?1313281620 If it is for an 03-07 XB you will need a hex socket tool. If the one that Texas_firebolt shows works then it would be easier than the one I show in the post. 08-10 models have bolts on both sides and are a lot easier. |
