The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Era Specific and Model Specific > Frame Mount EVO Sportster Talk (1986-2003 models)
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Notices

Active Threads
0 Chasing a generator noise
Last Post: DR DICK
Posted On: 2 Minutes Ago
Replies: 6
Views: 204
0 Installing jugs finally but another Q
Last Post: kitabel
Posted On: 4 Minutes Ago
Replies: 4
Views: 71
0 Hottie of the day, no nudity.
Last Post: trainman
Posted On: 4 Minutes Ago
Replies: 24,349
Views: 2,490,657
0 55* this morning
Last Post: sportsterpaul
Posted On: 10 Minutes Ago
Replies: 14
Views: 512
0 Sifton cams on stock 74 XLCH
Last Post: DR DICK
Posted On: 11 Minutes Ago
Replies: 3
Views: 30
0 Arlen Ness F-Bomb Pipe Test
Last Post: madnss
Posted On: 19 Minutes Ago
Replies: 23
Views: 8,094
0 2007 883R From Sunny Old England!
Last Post: sportsterpaul
Posted On: 27 Minutes Ago
Replies: 11
Views: 308
0 Keep & Kill
Last Post: Graywolf
Posted On: 37 Minutes Ago
Replies: 18,911
Views: 1,123,395
0 "The Blues" thread!
Last Post: Graywolf
Posted On: 39 Minutes Ago
Replies: 970
Views: 101,761
0 Pinion shaft holder tool
Last Post: Hippysmack
Posted On: 52 Minutes Ago
Replies: 2
Views: 48
0 Better Brakes
Last Post: RicThompson
Posted On: 1 Hour Ago
Replies: 23
Views: 1,517
0 Do you like Mexican food?
Last Post: Stairman
Posted On: 1 Hour Ago
Replies: 55
Views: 1,216
0 Covered shocks
Last Post: Heff
Posted On: 2 Hours Ago
Replies: 3
Views: 191
0 Xlh 883 oil tank paint
Last Post: John Harper
Posted On: 3 Hours Ago
Replies: 1
Views: 172
0 ....1
Last Post: Graywolf
Posted On: 3 Hours Ago
Replies: 5,923
Views: 341,649
0 starting rollers
Last Post: Ferrous Head
Posted On: 3 Hours Ago
Replies: 26
Views: 1,077
0 Potato-potato
Last Post: Highly-Dangerous
Posted On: 3 Hours Ago
Replies: 5
Views: 227
6 1983 Ironhead- Final wiring
Last Post: Attaxic
Posted On: 4 Hours Ago
Replies: 36
Views: 2,780
0 is a buell a harley
Last Post: Highly-Dangerous
Posted On: 4 Hours Ago
Replies: 174
Views: 26,935
0 Hot Rods, Rat Rods, and Customs.
Last Post: Stairman
Posted On: 4 Hours Ago
Replies: 4,299
Views: 643,301
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 5 Hours Ago
Replies: 48,941
Views: 7,937,177
0 Tools
Last Post: Eric Von Zipper
Posted On: 6 Hours Ago
Replies: 19
Views: 755
0 77xl sportster
Last Post: Steve9
Posted On: 7 Hours Ago
Replies: 10
Views: 284
0 XR750 resurrecting
Last Post: Steve9
Posted On: 8 Hours Ago
Replies: 30
Views: 2,038
0 You asked for it! "The Tess' Coffee Thread"
Last Post: Steve9
Posted On: 8 Hours Ago
Replies: 11,118
Views: 1,039,818
0 Microsquirt EFI Conversion
Last Post: Tomcatt
Posted On: 8 Hours Ago
Replies: 11
Views: 258
0 What did you do for your sporty Today?
Last Post: Highly-Dangerous
Posted On: 9 Hours Ago
Replies: 7,360
Views: 1,094,727
0 KBS tank sealer
Last Post: Len PA
Posted On: 10 Hours Ago
Replies: 17
Views: 768
0 Lets see your off season builds
Last Post: Iron Mike
Posted On: 11 Hours Ago
Replies: 1,465
Views: 217,917
0 Are There Still Sober Riders On The Forum?
Last Post: Reverend G
Posted On: 12 Hours Ago
Replies: 179
Views: 56,915
More...
Members Birthdays
lineberger, 39dan (62), FstPig (61), jmdajd (57), ironhead 74 (57), erjasn84, Bada Bing (56), ottchuck (55), OutlawTexan67 (53), RAJ (47), Wintersdark (44), robychopper (44), TnsporT (43), MotoSquirrel (36)
Reply
 
Share Thread Tools Display Modes
  #1  
Old 24th October 2020
John Harper John Harper is offline
Senior Master Custom Bike Builder
 
Join Date: Apr 2012
Posts: 3,612
Sportster/Buell Model: XLH 883/1250
Sportster/Buell Year: 1991
Reputation: 2396801
John Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond repute
Default 1991 Manifold Bolt Trivia (?)

My bike does not use a 5/16" Allen wrench, it takes a 1/4" Allen. I've pulled the manifold before, but never realized I used a 1/4" instead of the 5/16" mentioned by most sources. Interesting. Maybe not.

John
Reply With Quote
  #2  
Old 24th October 2020
rocketmangb's Avatar
rocketmangb rocketmangb is offline
XL FORUM TEAM MEMBER
 
Join Date: Jan 2008
Location: So Cal
Posts: 22,106
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: XL1200C
Sportster/Buell Year #2: 2006
Other Motorcycle Model: 48 "Totalled" By a Douche
Other Motorcycle Year: 2012
Reputation: 4480792
rocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond repute
Default

Its a 5/16 bolt,hence the 1/4 "
__________________
Thy Sportster Come
It Shall Be Done
On Earth as it is on Salt
2006 Sportster XL1250C
Hammer Sledge Heads 1.98X1.61 Valves
Hammer 600 Cams
Big Ass CP/Hammer Pistons
Mikuni HSR 45 /Hammer Billet Manifold (Now HSR 48)
Jetted 27.5 slow,182.5 Main
97 Needle,Clip posistion 3
Hurricane Flow 3" offset AC,Rocketman Mod
Daytona Twin Tec TC88A,Rico Scarecrow Map
Sumax Thundervolt plug wires,NGK DCPR8EIX spark plugs. Gapped .040 and Indexed
Cycle Electric Stator and Regulator
Alto Carbonite Clutch (now with Barnett Pressure plate and 25% stiffer spring)
Royal Purple 20W50 MC Primary oil
Patriot Defender Pipe
Royal Purple 20W50 MC Engine Oil
Napa 7148 oil filter
Max Power, 111.47
Max Torque, 84.39
Best 1/4 Mile ET to date 11.85
Best 1/4 Speed to date 115.14
Build by Jester Motorwerkz West
Reply With Quote
  #3  
Old 24th October 2020
John Harper John Harper is offline
Senior Master Custom Bike Builder
 
Join Date: Apr 2012
Posts: 3,612
Sportster/Buell Model: XLH 883/1250
Sportster/Buell Year: 1991
Reputation: 2396801
John Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond repute
Default

It's odd that I see recommendations for a Bondhus 5/16" Allen. From Hammer's instructions on conversion:

"A 5/16" T-handle hex key wrench (Allen) with a ball end and a long shank is a great tool for removing the upper manifold bolts. Bondhus offers a T-Handle set that's reasonably priced and works great.
A 5/16" L stubby type hex key wrench (Allen) will be needed to remove the lower manifold bolts. Many people cut down a standard L wrench. Bondhus makes a really nice set of stubby wrenches though."

I bought a 5/16" Bondhus stubby wrench a long time ago, could have sworn I used it when I changed manifold seals a few years ago. I guess not.

John
Reply With Quote
  #4  
Old 24th October 2020
rocketmangb's Avatar
rocketmangb rocketmangb is offline
XL FORUM TEAM MEMBER
 
Join Date: Jan 2008
Location: So Cal
Posts: 22,106
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: XL1200C
Sportster/Buell Year #2: 2006
Other Motorcycle Model: 48 "Totalled" By a Douche
Other Motorcycle Year: 2012
Reputation: 4480792
rocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond reputerocketmangb has a reputation beyond repute
Default

Yost makes a wrench,you can also use a garbage disposal tool !
I think I replaced mine with 12 PT aircraft screws
Reply With Quote
  #5  
Old 26th October 2020
John Harper John Harper is offline
Senior Master Custom Bike Builder
 
Join Date: Apr 2012
Posts: 3,612
Sportster/Buell Model: XLH 883/1250
Sportster/Buell Year: 1991
Reputation: 2396801
John Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond reputeJohn Harper has a reputation beyond repute
Default

Quote:
Originally Posted by rocketmangb View Post
Yost makes a wrench,you can also use a garbage disposal tool !
I think I replaced mine with 12 PT aircraft screws
I have a set of Bondhus stubby wrenches, just could have sworn I used the 5/16" last time.

John
Reply With Quote
  #6  
Old 1 Week Ago
farmall farmall is offline
Master Mechanic
 
Join Date: Jul 2013
Posts: 294
Sportster/Buell Model: XLH
Sportster/Buell Year: 73
Reputation: 567811
farmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond reputefarmall has a reputation beyond repute
Default

The 12pt bolts were used stock on the best HD intake ever, the Ram Jett one-piece manifold (no longer in production because it's not bling, they can be found on Ebay. The versions marked S are for Sportsters and are considerably narrower than big twin intakes. Most don't have the fasteners any more but it's easy to narrow the OD of common cap screws slightly on a grinder to clear the casting if needed. Ram Jetts don't need carb braces and are so stout I've sling lifted a big twin engine by the intake. The gaskets are easy to cut from Fel-Pro gray paper (any auto store). I installed my first in 1988 on my new FXR and threw the idiotic rubber boot intake (also used on early Evo Sporties) in the trash.

For wrenches I use a variety including brazing long sections of hex key into six point sockets (and an intermediate length section to do the old Keihin butterfly carbs on the bike without a tank pull). Best to buy a variety of T-handles, long hex keys and hex bits both ball and conventional for comfiest wrenching.
There are enough 5/16" and 1/4" Allen head fasteners having a variety of both sizes pays off.

It's worth playing with the "clock position" of the hex flat when torch bending wrenches so you never have a place where it's hard to get a bite.
Reply With Quote
  #7  
Old 1 Week Ago
carbonizedeyesockets's Avatar
carbonizedeyesockets carbonizedeyesockets is offline
XL FORUM TEAM MEMBER
 
Join Date: Feb 2016
Posts: 63
Sportster/Buell Model: Sportster XL883 /1275
Sportster/Buell Year: 2004
Sportster/Buell Model #2: Sportster XL1200
Sportster/Buell Year #2: 2002
Reputation: 17024
carbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to allcarbonizedeyesockets is a name known to all
Default

I wondered this too. Now I know
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT +1. The time now is 01:49.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC