Doing intake gaskets. First time. What else should I do while I'm there?

[motoguy]

I'm going to replace intake gaskets as general preventative maintenance (my fuel pump crapped out, so I'm done for a bit). 06 Uly 4x,xxx miles. Going to rotate the engine to do the intake gaskets. I plan on purchasing the Oberon gaskets. Sounds like they're the best bet for longish term fix.

This is my first real service on the XB. What else should I do while the engine is rotated? I don't appear to have rocker box leaks, but should they be swapped while I'm there? If so, recommendations on brand? Sounds like replacing the O2 sensor would be a "never easier than now" thing as well. Same with cleaning injectors.

Other input?

 

[Pushr0d]

Check the rocker box vent valves to ensure they function one-way, and replace the grommets. Very common source of escaped oil down the front and back of the cylinders.

Saying that - clean, clean, clean! It's amazing how much crap accumulates in all the nooks and crannies.

Pay close attention to how the wiring is routed around and over the engine - assuming a PO didn't dork it up like on my bike. For instance, the IACV motor leads go into a harness that clips into plastic 'brackets' to keep it off the rocker box. Mine was just draped over the engine, and the harness cover was worn through in one spot.

TESA tape is a great means for worn or failing tape. (https://www.amazon.com/Tesas-Advanc...ocphy=9011614&hvtargid=pla-406190500764&psc=1)

 

[Barrett]

^^^^^^^^^^^^^^^^^^^^^^
Steve: Brilliant advice as always. And that tape is pretty damn awesome. I have used the 3M super sticky cloth-type tape but the tape in your link even nicer.
REPLACE the grommets Steve mentioned. They are always hard brittle leakers and can only be replaced with engine flipped forward.

GROMMET INFO: HARLEY DAVIDSON PART # 17606-00YA (SUFFIX L6B7)...........TWO REQUIRED...LIST IS $9.40 EACH. EXCESS OF 100 STILL LISTED IN DEALER SUPPLY CHAIN. AVAILABLE THRU ANY DEALER.

 

[MC Hammered]

I used an ultrasonic cleaner to clean the TB, all of the hardware and replaced the rocket box seals and grommets while the engine was dropped.

I would recommending replacing the PCV valves as the original ones are probably saturated by now.

 

[motoguy]

Thanks for the info. I'll get some grommets and rocker box gaskets on order. This thread is a bit of a reminder to myself. I'll also check the throttle body shaft while I've got it apart. I don't remember if 06 has that issue, or just '07.

 

[Cooter]

If you don't feel like rotating the engine, you don't need too. A fairly well stocked toolbox will have the stuff for the fiddly bits, here's a list and some tips:
https://www.buellxb.com/forum/showthread.php?57534-XB-intake-seals-swapped-in-45-minutes
and more detail:
https://www.youtube.com/watch?v=UjWWUE9qrkw
I didn't need it, but I hear this helps:

The TB and it's flanges only go on ONE way, the injectors are front/rear specific, I haven't had issue with OE seals and NO special sealer goo, but they seem to squish around if you overthink it and try to add stuff the factory didn't need.

If you DO rotate it even though you don't have too, Ya, replace the PCV grommets, Rocker box seals, O2 sensor, and heck, that belt is getting to the mileage that people post it snaps at. 50K.

 

[motoguy]

If you don't feel like rotating the engine, you don't need too. A fairly well stocked toolbox will have the stuff for the fiddly bits, here's a list and some tips:
https://www.buellxb.com/forum/showthread.php?57534-XB-intake-seals-swapped-in-45-minutes
and more detail:
https://www.youtube.com/watch?v=UjWWUE9qrkw
I didn't need it, but I hear this helps:
View attachment 17208
The TB and it's flanges only go on ONE way, the injectors are front/rear specific, I haven't had issue with OE seals and NO special sealer goo, but they seem to squish around if you overthink it and try to add stuff the factory didn't need.

If you DO rotate it even though you don't have too, Ya, replace the PCV grommets, Rocker box seals, O2 sensor, and heck, that belt is getting to the mileage that people post it snaps at. 50K.

Thank you! Your video is what prompted me to see if engine rotation was required for this task! lol

It sounds like there are enough worthwhile things to do (rocker box gaskets, breather valves and grommets, O2 sensor) to warrant the engine rotation. I want to get the new-to-me bike to a known good baseline mechanical condition, and this sounds like a good start.

 

[Cooter]

It is a fantastic start if you enjoy that type of thing. I know I do:angel:

I hate to say it, but an 'engine rotate' is only a couple bolts away from just removing the dang frame anyway. I have never just 'rotated' a Buell. It's kinda wonky and unstable, so depending on the job, I either fiddle in tight spaces or totally remove the frame. Worth it to drill a hole in a couple pieces of square stock that bolt to the front of the engine to make a tri-pod with the rear wheel

I did rotate the EBR once, and never again. It's so easy to just continue and remove the frame entirely, I do it for annual maintenance (#track bike lyfe, lol).

Sometimes two in a day! haha.

 

[Pushr0d]

Cooter - is that '57 still all over your shop? I'm guessing the photo probably shows only a bit of the 'distribution'.

 

[Cooter]

UGH, yes. (Hides head in shame). Most everything is on those shelves in the back. I have put a lot of the chassis together to make a roller but dang if every stinking thing needs to be modified before it "bolts-on".
And the "low-mile" 6.0L is frozen too:mad-new:

 

[motoguy]

I used an ultrasonic cleaner to clean the TB, all of the hardware and replaced the rocket box seals and grommets while the engine was dropped.

I would recommending replacing the PCV valves as the original ones are probably saturated by now.

Have aftermarket replacements for the PCV valve been identified? $47 each for a PCV from St Paul seems a bit steep.

New fuel pump has arrived, intake seals ordered from Twin Cycles, will pick up the grommets from my local dealer this week. Any vendor / brand suggestions for a "one and done" set of rocker box gaskets? I'll pick up some of that TESA tape as well. I'll need to do some searching here to find which O2 sensor I need to buy while I've got it apart.

 

[Cooter]

For the rocker box, I have used Cometic, OE, and James, all without issue. I deviate from the factory manual slightly by dabbing a SMALL amount of High temp RTV in the 4 corners about 1" long. Don't forget to tighten the rockerbox s.l.o.w.l.y. as you re-torque. That allows time for the lifters to compress, or you can bend pushrods:down: And keep the pushrods marked for location, they are slightly different lengths.

I have used the Bosch 12014 as a O2 sensor replacement several times but lately questioning its functionality YMMV.

Heres a good reference for your next thread
https://www.buellxb.com/forum/showthread.php?26310-Parts-cross-reference-thread

 

[Barrett]

Have aftermarket replacements for the PCV valve been identified? $47 each for a PCV from St Paul seems a bit steep.

New fuel pump has arrived, intake seals ordered from Twin Cycles, will pick up the grommets from my local dealer this week. Any vendor / brand suggestions for a "one and done" set of rocker box gaskets? I'll pick up some of that TESA tape as well. I'll need to do some searching here to find which O2 sensor I need to buy while I've got it apart.

Have aftermarket replacements for the PCV valve been identified? $47 each for a PCV from St Paul seems a bit steep.

YES

 

[motoguy]

I have used the Bosch 12014 as a O2 sensor replacement several times but lately questioning its functionality YMMV.

I'm putting together a parts list. I'm curious what you mean by this statement. Does it appear this is not an acceptable alternative after all?

 

[motoguy]

I'm curious about the failure rate on the head temp sensor. It seems the temp sensor is the only thing left that might benefit from replacement while the engine is rotated. At $90, if it's a low failure rate item I might just let the old one remain.

I'm planning on replacing:

intake seals
PCV grommets
PCV valves
rocker box gaskets

Pull and ultrasonic clean the throttle body
have injectors cleaned

 

[Cooter]

More than once I have replaced a Buell O2 with the Bosch one and then had to chase a sinking AFV issue. Not sure where that Bosch number was sourced from anyway, so I've just been going OE and not had an issue.

FYI, I have never actually tested or diagnosed this, so it's just a running theory.