Changing the carb intake boots on 82 Maxim 650

Does anyone know where I can find a good walkthrough to change the intake boots? The boots on my bike are SERIOUSLY dry rotted, but i found some good used ones for cheap ($50!?!?). The only problem, i am a complete novice when it comes to making the switch, and I don't want to screw up my bike.

 

:::: WARNING ::::
:::: Removing Manifold Fasteners can cause a maintenance nightmare. ::::

Manifold Fasteners are prone to SEIZURE.
They are cheap, soft-steel and EASILY twist and BREAK.
Breaking-off a Manifold Cap Screw fastener creates a very complicated, labor intensive nightmare.
The broken fastener could require removal of the Cylinder Head and Machine Shop work to remove the fragment and repair the Head.

 

I just replaced all my boots with new ones . I used kroil oil as a pre soak of the bolts . this stuff is amazing it penetrates like crazy and my bolts came right out . You do want to use some sort of penetrating oil and let it soak for a few days with several applications over those few days !

 

Also you must order the new intake gaskets . you can probably get them here from chacal or i bought my new boots vacuum caps clamps and gaskets from a place called babbitts . these are straight from yamaha . .

 

so, be careful with the bolts. need new intake gaskets. Can I use generic paper gasket, and cut to fit, or will that cause problems?

 

You can use Home-made Gaskets.
The Intake Manifold Gaskets are simple to make.
Trace an old one.

Or, ... Color the Intake Port with Lipstick.
Press a Sheet of Paper to the Intake transferring the color to the paper.
Carefully cut-out the pattern and trace it on Gasket Paper.

 

Does anyone apply anything to the gasket or intake boot (ex. indian head gasket shellac) before install? Getting ready to reinstall my old intake boots and I got new gaskets. All my bolts came out without a hitch and only a couple days of penetrant soak. Also what should I torque the bolts to...5-7 ft lbs?

 

Cool, so i just need to find my sheet of paper gasket i have laying around. Thanks for all of the helpful tips!

 

While we are on this subject.... can I use RTV for gasket? not really worried about this being some top notch job,, just a quick fix. also, how the hell do you put these and the carbs back on? i tried first to put on the intake boots, tightened down, then the carbset.. but the cars wont pop onto them. I tried warming with a heat gun, still not going on.. I tried to take the two inside ones off, put them on the carbs, then get the outside two to snap on the carbs, worked, but I cant tighten the inner two. guess i could reverse that, leave the two inners on the head and take off the two outer boots and slip them on the carbs, those bolts are easier to get, but is that the best way to reinstall? by the way, my bolts came off pretty easy, whew, i saw this AFTER removal.

 

Soak them in boiling water for several minutes

 

Soak them in boiling water for several minutes

http://www.xjbikes.com/Forums/viewtopic ... moval.html

 

Did anyone else get that Rick has lipstick??

Ducky, you shouldnt break the carb rack unless you have to!
I use a long rod and use leverage and push the carbs into the boots. I usually pry from the bottom-ish right in the center, and push in either or side with my other free hand. Pops right in

 

I wouldn't. And there's no such thing as a "quick fix" that idea will quickly come back and bite you.

All four manifolds should be mounted on the motor and torqued to spec, 7.2 ft/lb.

Remove the airbox mounting bolts, letting it flop about will gain you some room. When you slip the rack into place, start with the intake throats pointed downward, and engage just the upper edge of the manifolds. Then as you push it into the boots rotate it down at the rear; as it comes level the carb stubs should pop right in.

 

Thanks everyone. I did see another post, shortly after I posted here, that explained the same things you have described. Since I am planning on doing some more extensive work to this over the winter, Hopefully, I decided to use blue rtv. My knowledgeable, hasnt failed me yet, mechanic said, aluminum to aluminum intake, can use blue rtv as it will not be affected by the gas. I wasnt going to waste the money on gaskets jsut for a few months of play time on this bike.

Sitting on the bike and popping it in went very easy,, 10 seconds at the most! And no, i did not take the carb rack apart, i would never do that!

thanks again everyone.

 

Rick, that's AWESOME

 

You're missing out on alot of fun !! :lol:

 

I meant I wouldn't ever do it unnecessarily! I will be rebuilding these carbs over the winter.

 

I'm getting ready to replace the intake manifolds on my bike and have opted to cut out my own gaskets. However I'm not sure what type of gasket material to use that would be more of a high performance option or the proper thickness. Any recommendations?