How to: Remove intake manifold velocity stack : With Pics!

OK! I googled a lot and have not found any helpful information how to remove intake manifold velocity stack. You may not pay serious attention this little piece of rubber, but so far it looks like removing velocity stack is the most difficult thing in the engine rotation process. The next most difficult thing is only removing breather hoses from the airbox baseplate, but it is not as bad as velocity stack removing. So I think this deserves dedicated thread to help you do not stuck at the velocity stack.

I maintained the 2009 Buell XB12Scg, maybe they updated the velocity stack, maybe the rubber has been hardened in time under temperature, but there is no way in hell to remove this thing as it described in service manual, because you just physically will not be able to pull this out manually.

So to successfully remove the velocity stack you will need to squeeze the velocity stack metal ring tips using pliers (you also can use zip tie to help to hold the ring squeezed but it is not necessary if you have a good or appropriate pliers.)






Move the metal ring all way up.






Prepare long breaker bar or metal pipe, piece of wood and a strap.





Put the piece of wood on the frame above the fueling hole cover, bind the strap around the velocity stack tightly, make a loop around the breaker bar, pull the velocity stack up using the breaker bar as lever like it showed on the picture below.






Done! You can see how deep the grooves in the velocity stack so I am not sure that it is possible to remove this thing with bare hands, even with long lever it was pretty difficult to pull this up.

My 04 model stack just popped off with my fingers under it. That wire clip is a pain in the ass though so i replaced it with a stainless hose clamp.

I used a Front-end loader and hung the bike by the stack. I then shook the bucket and it popped right off but my bike fell over. At least I got it off and that was the goal. They end.

^^^^that's what I call redneck ingenuity! :up:

rchuff said:

I used a Front-end loader and hung the bike by the stack. I then shook the bucket and it popped right off but my bike fell over. At least I got it off and that was the goal. They end.

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flame-thrower here ricky. velocity stack eventually came off but sadly not much left of my beloved cityX. was thinking front-end loader or bob-cat as well but don't have the access to heavy equipment as you do.

Well, it apparently works, I would think that is an enormous amount of pressure on that rubber, I'm really surprised that it didn't split ! Good write up and pictures, I'm sure I'll have to do this someday.

Thanks

Simplymichaeljr said:

^^^^that's what I call redneck ingenuity! :up:

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Redneck enginuity would be hollerin to yer ole lady, smokin Marlboro reds in yer trailer, to come out yonder and give yin a hand yanking that thang!

buell248 said:

I'm sure he had his Chuck Norris shorts and boots on when he pulled that stack off!
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and as an added bonus dave....he called the mighty chuckster for a phone "walk thru" during the removal process. clearly from his facial expression, chuckster wasn't all too thrilled with the call.

The shorts and the boots with tube socks on made it easy for me to get into the loader but my cat like reflexes couldn't keep the bike from falling over. They end again. Ps let me know next time John, I will bring the John Deere 333 skid steer over and we will get that bad boy off quick!