| Author | Message | ||
     Keith  |
A couple of weeks ago, I diagnosed my 2003 XB9S as having an intake manifold leak. Normally, changing the intake seals on a Harley is pretty straightforward. However, I dreaded tackling this job on the Buell due to a perceived lack of access on the XB. The shop manual further reinforced this as it said the engine must be rotated for this job. What I found was not only can changing the seals be accomplished without rotating the engine, it really was not that difficult and required few special tools.  The first tool at the bottom of the photo is made by Yost specifically for the intake manifold fasteners on Harley style engines. It gave me access the right-hand, front bolt. The next tool is a shortened 12 point 13mm box end wrench that let me loosen and retighten both bolts on the left side of the manifold. The fact that it is a 13mm, 12-point wrench made it much easier to get to the bolts. Not much torque is required so there was no problem with rounding of the bolt head. The third tool is a ball end hex bit that along with a ¼” open end wrench, let me loosen and tighten the right-hand, rear manifold bolt. A ¼” universal joint (which I do not have) would have made getting to the manifold to frame bolt easier. Once the bolts were removed, the manifold/injection assembly can be gently moved to allow the seals to be removed and replaced. You simply reverse the procedure to complete the job. The piece of spiral wrap is shown in the photo as this is what was used to protect the TPS and injector wiring that was rubbing against the right hand side of the frame. I can only imagine what it would have been like to be several hundred miles from home and have one of those wires short out! Any way, I hope this helps anyone who may be contemplating this job. I went ahead and changed the plugs while I had access to them. Keith | ||
| Hogs |
Hey Keith,, Niceeeeeeeeeee Great Thanks for that TiP.. Its worth its weight in Golddddddd | ||
| Ingemar  |
Cool. Thanx for sharing that. Did it help? You had some problem if I remember correctly right? | ||
| Keith |
Yes, it corrected the stumble and sputter that I was experiencing in the 3-4k RPM range. I kept telling myself that nothing was wrong, but some contact cleaner sprayed around the intake manifold where it bolts to the heads with engine running produced an increase in engine speed. I took it for a spin yesterday and she runs like a top! Keith | ||
| Ingemar |
Good stuff! | ||
| Easyflier |
That's some helpful info Keith, thanks. I have to pull the heads off my bike for other repairs but it's good to know that it can be done in the frame with some patience and the correct tools. | ||
| Glitch  |
Thanks S k u l l y!  | ||
| Keith |
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| T9r |
This helped a lot, Thanks Here is my tear down: http://www.badweatherbikers.com/buell/messages/32777/207693.html?1150977116 |
