Differences

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--- techtalk:evo:carb03a [2019/04/09 19:33]
hippysmack [Installing the Seals]
+++ techtalk:evo:carb03a [2019/04/09 20:38]
hippysmack [Installing the Intake]
@@ Line 22: / Line 22: @@
 The flanges are directional. There is a letter stamped on each flange for (F) - front or (R) - rear placement. \\
 There is a mounting hole on one side and a mounting slot on the other. \\
-The slot goes toward the 'tight side' between the cylinders or otherwise toward the left side of the bike. \\
+The slot goes toward the 'tight side' between the cylinders ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) or otherwise toward the left side of the bike. \\
+If you look at the flanges it should cause a bad mis-alignment if you use them the other way. ((rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\
 |{{:techtalk:evo:carb:intake_manifold_flanges_2_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_flanges_1_by_hippysmack.jpg?direct&300|}}|
@@ Line 35: / Line 36: @@
 ====== Installing the Intake ======
+Although this can be done with the fuel tank on, it's easier if you remove it. \\
+The idea is to align the manifold & the carb BEFORE tightening everything into their final positions. ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\
+This will help to prevent air leaks. \\
+Normally, the slotted holes of the manifold flanges go in the tight side & the round holes go outward. \\
 |Install the intake with the slots toward the left side of the engine. \\ Leave the bolts loose until you install the carb. ((photos by Hippysmack))||
@@ Line 45: / Line 50: @@
 They they will be pulled away from there mating surfaces while following the rotating carb position. \\
-|Install the carb and carb support. \\ (air cleaner backing plate) ((photo by Hippysmack))|Getting to the carb side bolts isn't easy from this \\ point of view. ((photo by Hippysmack))|
+To align the carb to the intake, you can temporarily mount the carb: ((IXL2Relax of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=9)) \\
+  * Remove the rubber seal at the manifold mouth.
+  * Put the carb (on it's bracket) in place (bracket bolted to the heads). \\ (to see if the carb aligns properly with the manifold intake opening)
+If the carb doesn't set nicely in the middle of the manifold opening:
+  * You probably need to move the manifold or the carb until that alignment is achieved.
+If this alignment is right, later, when the rubber seal is in place, the carb will fit right in & you'll have less chance of intake air leaks.
+Or, you can final mount the carb in place:
+  * Remove the front left motor mount to gain access to the intake with both hands. \\ This also gives you easier access to the intake mounting bolts)
+  * Install the intake on the heads with the carb seal in place.
+  * Leave the intake mounting bolts loose.
+  * Line the inside of the seal with water or a thin film of oil to help the carb slide into it. \\ (you can also use a dab of water and dish soap solution)
+  * Install the carb in the intake, the air cleaner on the carb and install the carb support on the heads loosely.
+  * Then wiggle the intake up/down and visually inspect the seal top to bottom for evenness.
+  * Torque the crab support bolts.
+  * Then torque the intake bolts.
+  * Recheck the seal for evenness.
+  * Reinstall and torque the motor mount.
+|Install the carb and carb support. \\ (air cleaner backing plate or other aftermarket) ((photo by Hippysmack))|Getting to the carb side bolts isn't easy from this \\ point of view. ((photo by Hippysmack))|
 |{{:techtalk:evo:carb:intake_manifold_10_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_11_by_hippysmack.jpg?direct&300|}}|
+You can use a long ball type Allen wrench on the intake bolts. \\
+But it may be difficult to get them fully inside the screws at the angle you're at. \\
+If so, it will be difficult to get them torqued as the wrench will slip out of the screw socket. \\
+That's where removing the top left motor mount comes in handy also. \\
+You can get both hands in there to install the wrench with variations of where you can pull from. \\
 |If you remove the top left motor mount, you'll have \\ easier access to the intake bolts. ((photo by Hippysmack))|Then you can get both hands in there to install \\ the wrench with several pulling options on the bolts. ((photo by Hippysmack))|
 |{{:techtalk:evo:carb:intake_manifold_14_by_hippysmack.jpg?direct&300|}}|{{:techtalk:evo:carb:intake_manifold_12_by_hippysmack.jpg?direct&300|}}|
+Do not over-torque the intake bolts. This will probably cause a leak. \\
+|  Example of seals with over-torqued bolts. ((photos by Matt Black of the XLFORUM http://xlforum.net/forums/showthread.php?t=2068828&highlight=intake+manifold&page=8))  |||
+|{{:techtalk:evo:carb:intake_bolts_too_tight_1_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_2_by_matt_black.jpg?direct&200|}}|{{:techtalk:evo:carb:intake_bolts_too_tight_3_by_matt_black.jpg?direct&200|}}|
 \\

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