Main Menu
|
Active Threads
|
Keep & Kill
Last Post: Crusty
Posted On: 4 Hours Ago
Replies: 19,450
Views: 1,160,479
....1
Last Post: Graywolf
Posted On: 20 Hours Ago
Replies: 5,972
Views: 347,542
|
Members Birthdays
|
|

24th October 2020
|
Senior Master Custom Bike Builder
|
|
Join Date: Apr 2012
Posts: 3,643 Sportster/Buell Model: XLH 883/1250 Sportster/Buell Year: 1991
|
|
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
|

24th October 2020
|
 |
XL FORUM TEAM MEMBER
|
|
Join Date: Jan 2008
Location: So Cal
Posts: 22,186 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
|
|
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
|

24th October 2020
|
Senior Master Custom Bike Builder
|
|
Join Date: Apr 2012
Posts: 3,643 Sportster/Buell Model: XLH 883/1250 Sportster/Buell Year: 1991
|
|
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
|

24th October 2020
|
 |
XL FORUM TEAM MEMBER
|
|
Join Date: Jan 2008
Location: So Cal
Posts: 22,186 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
|
|
Yost makes a wrench,you can also use a garbage disposal tool !
I think I replaced mine with 12 PT aircraft screws
|

26th October 2020
|
Senior Master Custom Bike Builder
|
|
Join Date: Apr 2012
Posts: 3,643 Sportster/Buell Model: XLH 883/1250 Sportster/Buell Year: 1991
|
|
Quote:
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
|

19th November 2020
|
Master Mechanic
|
|
Join Date: Jul 2013
Posts: 294 Sportster/Buell Model: XLH Sportster/Buell Year: 73
|
|
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.
|

20th November 2020
|
 |
XL FORUM TEAM MEMBER
|
|
Join Date: Feb 2016
Posts: 77 Sportster/Buell Model: Sportster XL883 /1275 Sportster/Buell Year: 2004 Sportster/Buell Model #2: Sportster XLH1200 Sportster/Buell Year #2: 2002
|
|
I wondered this too. Now I know
|
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
|
|
Thread Tools |
|
Display Modes |
Linear Mode
|
Posting Rules
|
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
HTML code is Off
|
|
|
All times are GMT +1. The time now is 09:36.
|