Replacing intake gaskets (DIY TUTORIAL)

[BuellyBagger]

or if I had some damage to the sealing surfaces, then yeah James may be the way to go.

that i can see as a good reason. I'm guessing it would take a bit of common sense (i know there's no class for that right now so its really a pointless phrase). Installing them by tightening them snuggly enough to seal but not over doing it so to bend anything. I do throw torque specs out the window on those kind of things... i torque my axles and suspesion part fasteners and what not but somethings just require the " feel"

 

[njloco]

That's what she keeps on telling me !

 

[El_Beardo]

I bought the OEM style black gaskets and won't be rotating the engine. Hopefully it works out, or check Craigslist in a few days for a cheap XB12R...

 

[34nineteen]

Get some of the u shaped offset wrenches or buy some inexpensive ones to cut down and make stubby to make this job easier. I had cut down an old 1/2 wrench to nothing more than the end and maybe about 1” of shaft.

This job will likely take about 2-3 hours your first time. Takes about 15-20 minutes on a Sportster, if you’re taking your time.

 

[njloco]

I hope your exaggerating, getting rid of your Buell just because end up having to rotate your engine. While I haven't done it first hand, everyone here that has,, has said it's actually not that difficult.

Good luck.

 

[TPEHAK]

It's not difficult, but it takes a lot of time. And there is no big difference in difficulty if you change intake gaskets with or without rotated engine. Without rotated engine there is slightly more difficult to reach one screw on left side of intake manifold, the rest is the same, but if you will rotate engine changing the intake gaskets will take you much more time. And remember that you have to perform leakage test after replacing gaskets and there is 80% chance that they will leak and you will do this work again and again. So do not rotate the engine.

 

[Cooter]

I agree with some of TPEHAK's statement. You should plan a whole day for your first rotate, and I also think it's unnecessary for an intake gasket swap.

I highly disagree with TPEHAK's statement that 80% will leak again. That is ludicrous. That would require a re-design of probably millions of similar motorcycles. It's his one experience with his one motorcycle, and he is definitely not a mechanic. His one experience he's touting as a fact for all Buells does not make it true for millions of Buell/Harley intake gaskets as a whole.

In just the last 10 years, I've swapped intake gaskets on Sportys or Buells about 3 times a year. Thats 30-ish jobs (60 gaskets). Not one has leaked. Ever. I must be luckier than I thought:angel:

Just be patient, take your time in the tight space, use the right tool, use lube, and you will be rewarded with her sucking only where she's supposed too.

 

[El_Beardo]

Quick question - in the middle of the job - does the top opening method only work for older bikes with the smaller air hole in the frame? I noticed the pics from various sites all show that and my bike is newer (2009) and I am unable to get the flanges to clear the heads.

 

[34nineteen]

The flanges will float freely on the manifold. It’s likely the seals are sticky and holding the flanges in place.

 

[David Borthwick]

Great write up for doing the seals. It is a shame that Tpehak or whatever he is called hijacked it and spoilt it. I have only just recently joined this forum, have read many threads and have come to the conclusion that he doesn't know what he is talking about, indeed he is almost trolling all the threads he goes on!

 

[BuellyBagger]

Great write up for doing the seals. It is a shame that Tpehak or whatever he is called hijacked it and spoilt it. I have only just recently joined this forum, have read many threads and have come to the conclusion that he doesn't know what he is talking about, indeed he is almost trolling all the threads he goes on!

Well you my friend are a quick learner! Welcome aboard

 

[Ptech]

Started to replace mine tonight, little tip. Remove the bracket for the coil. It will open up a huge area, the bottom bolts can now be loosened with ease.

 

[Binks_no_Sake]

Hello there!
this thread was like a spanish telenovela when TPEHAK joined
Anyway, thank you all for all the relevant input.

Got my 08 XT uly with 30k miles 4months ago and from a start it suffered with a lean AF on the rear cylinder... So i ran closed loop with AFV hard set to 100/100(about right for my elevation) and bike runs kinda fine.

As i had a bit of a brainfart i didn't google "seal intake leak" and thought it's just about the airbox... *******...
AFV constantly around 70-80 on the rear, occasionally hiccups in the intake and quite bad fuel economy...35mpg best i had on 20miles in constant 65mph ( highway test run)
Had ECM reflashed to latest firmware, changed sp.plugs and o2 sensor. No change... and then i finally googled the *intake seal leak* and it just explains everything...
But to be on the safe side, i'll replace TPS as well