1991 Manifold Bolt Trivia (?)

[John Harper]

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

[rocketmangb]

Its a 5/16 bolt,hence the 1/4 "

[John Harper]

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

[rocketmangb]

Yost makes a wrench,you can also use a garbage disposal tool !
I think I replaced mine with 12 PT aircraft screws

[John Harper]

Originally Posted by rocketmangb

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

[farmall]

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.

[carbonizedeyesockets]

I wondered this too. Now I know