Today we're going to go through the process of changing your intake manifold seals. After all, you can't spend all your time installing bling bling blue LED lights on your bike all the time.
I usually replace these about every 2 or 3 years. It been about 2 years now.
First thing to do is remove the seat and gas tank. If you really want to play it safe unhook the battery positive cable. If you need instructions how to remove the seat, go no further. PUT YOUR HANDS UP AND BACK AWAY FROM THE TOOL BOX.
Assuming we got through that alright, remove the air cleaner cover, and filter element. You should now be looking at something like this.
Unhook your vacuum line to the VOES.
Use a Bonhaus driver to remove the allen bolts on the top side of the intake manifold flange. This is nothing more than a ball end allen wrench. Use a 1/2" wrench to loosen the 2 bolts on the bottom side of the intake manifold flange
Now that all 4 of the intake manifold bolts are removed, it's time to remove the 2 bolts that hold air cleaner back plate to the heads. If your bike is a 5 speed your bolts are hollow to allow for the head breathers.
Now you should be able to remove the entire intake manifold, carb, back plate assembly. Notice I didn't bother removing the throttle cable, because I'm not planning to do any work on the carb other then replacing the manifold seals.
I like to apply grease on the seals before installation. That's my secret to never having a intake leak.
Here's a new seal already installed.
Don't forget to clean where the seal fits to the head.
Now we ready to install the intake assembly. Notice one side of the flange has slots instead of bolt holes. Position the slots so that they're aiming down and forward. As you push the intake assembly into position, make sure the slots in the flange engage the studs on the bottom of the intake ports.
It's helpful if you can get some longer than normal bolts to screw into the heads and air cleaner back plate to hold the assembly in place while you installing the nuts and blots on the manifold flanges.
If you've got big hands it's helpful to use a magnet to help install the allen bolts in the flanges.
Now tighten the 4 intake manifold bolts. Basically you tighten the bolts till the flanges bottom out to the heads. Torque spec is 6-10 ft lbs. In other words, not all that tight. I never use locktite on any of them either, but I know you want to.
Last thing is to install the correct spacers between the air cleaner back plate and the heads, and then tighten the back plate down. 10-12 ft lbs. Now we're back were we started.
Put the gas tank and seat back on. Don't forget about the battery if you unhooked it, and install the air filter element and cover. Now it's time to ride.
How to replace Intake Manifold Seals
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