INTAKE BOOTS!!!! THE AGONY!!

i have an 82 xj650 maxim, all of my intake boots from the carb to the cylinder are dry rotted, 2 of them have decent size splits in them, and are rigged up with tape and hose clamps, but the combination of the fuel vapor and extreme heat just turns any roadside repair into a slimy mess!! does anybody know of any substance (resistant to gasoline and high heat) that will repair these ripped boots once and for all?? my wallet is hurtin' and im not looking to spend the money on new boots if i dont have to.. liquid electrical tape maybe?? any thoughts? questions? answers? advice? greatly appreciated!!! remember, these boots arent just cracking, one of them is split nearly halfway around!


Thanks!!

 

If they're that bad, i really don't think there's much you can do but buy a new set of 4. I Would just so i wouldn't have to worry about it.

 

One common repair is to get a bicycle innertube and cut some sections that stretch and slip onto the outside of the boots. To install, slather the outside of the boot with black RTV, slide the innertube section on, and use more RTV to seal the edges of the innertube section. Let it cure, and try it out. Of course, if yours are too cracked, especially around the edges where it goes over the carb, you may be out of luck.

Dave

 

wow that inner tube fix sounds like a great idea, ill have to give that a try!! theyre only ripped in the open gap between the flange and carb, so this seems like it could work if done right, thanks!!! and i know eventually i'll end up buying 4 new ones, but anything that will prolong the life of these will work for now. thanks guys!

Erik

 

I have tried the black rtv stuff on mine and it works well. Just be sure to allow proper drying time before riding again. Good Luck.

 

I feel for you. I got lucky and found a person on Ebay who didn't know what she was selling. Got 4 of them almost like new for 40 bucks. I think they are made of a gold alloy for what they sell new.

 

Well I repaired them with the pieces of inner tube, but i did not use RTV silicone, i felt that the inner tube itself was stretched tight enough to seal it up, and it does for the most part. But the problem is, the boot is cracked through the little concave section (area where mounting bolt is located) and apparently I'm not getting a good seal in that area. I'll try using additional hose clamps to snug it up a bit, and if that doesn't work it's coming back apart and getting lathered up with silicone!!

 

I can't remember exactly where I saw them, ... (maybe on the site of those guys who make the New Diaphragms) ... But, ... there's a firm offering Intakes that were affordable.

 

I've seen them on EBay for $84 for the set. (1982 xj550)

 

do you know if they are interchangeable with the 650 model? I'm sure i can find something thats not specifically for my bike, but would work the same (if not better in my case) as the factory boots.

 

No, they are not interchangeable.

Dave

 

i figured that.. how about the seca 650s ? do they have YICS as well?

 

Is it possible to take the 82 YICS intake boots and flip the left two upside down to fit an 81 xj650? (nonYICS)

 

No. See Fitz's post in the thread you started.

 

I found mine on Fleabay (georgefix) for about $80.

 

Len has them for a bit less. PM Chacal.

http://www.xjbikes.com/Forums/viewtopic/t=44642/postdays=0/postorder=asc/start=15.html



XJ650, XJ700, and XJ750 engines:

NOTE: the non-YICS (1980-81 XJ650 Maxim/Midnight Maxim and 1982 XJ650RJ Seca) left side (cylinders #1 and #2) manifolds differ from the YICS (1982-84) manifolds in the orientation of their mounting:

* non-YICS engines have the intake manifold mounting bolt holes in the cylinder head aligned in this manner:

<#1 \ \ \ \ #4>

* YICS engines have the intake manifold mounting bolt holes in the cylinder head aligned in this manner:

<#1 / / \ \ #4>

This is why the left side (cylinders #1 and #2) intakes differ between the YICS and non-YICS engines, and why they are the same for the right side (cylinders #3 and #4) on all XJ650 non-Turbo engines!

HCP535LH OEM Yamaha rubber INTAKE MANIFOLD, used on the two left cylinders (#1 and #2). Manifold only; you must order all accessory pieces (manifold-to-head gaskets, nipple plug caps, bolts, etc.) separate. Fits all 1980-81 XJ650 Maxim, XJ650 Midnight Maxim, and 1982 XJ650RJ Seca models, and all 1980-81 XJ650 Euro models. Each:
$ 69.95

HCP536RH OEM Yamaha rubber INTAKE MANIFOLD, used on the two right cylinders (#3 and #4). Manifold only; you must order all accessory pieces (manifold-to-head gaskets, nipple plug caps, bolts, etc.) separate. Fits all 1980-81 XJ650 Maxim, XJ650 Midnight Maxim, 1982 XJ650RJ and RJC Seca, and all 1980-81 XJ650 Euro models. Each:
$ 79.95

HCP21225 OEM Yamaha rubber INTAKE MANIFOLDS, complete set of 4 intake manifolds (2 left and 2 right). Manifolds only; you must order all accessory pieces (manifold-to-head gaskets, nipple plug caps, bolts, etc.) separate. all 1980-81 XJ650 Maxim, XJ650 Midnight Maxim, 1982 XJ650RJ Seca, and all 1980-81 XJ650 Euro models. Set of 4:
$ 279.95

 

I know I'm a bit late coming into this post, but wanted to add some info and ask a question of my own if any are still following this...

For everyone who owns the xj1100 maxims the intake manifolds are running really cheap on amazon at the moment: 64.50 for all four - brand new!

http://www.amazon.com/Yamaha-Intake-Man ... take+boots

Now my question: will these work with my 81 xj650 non-yics engine?

I know it's a long shot, but man this would be so much easier on the wallet. If necessary I am willing to put the money in to the boots chacal has to keep my bike running in good condition.

Thanks everybody!

 

the XJ1100 boots are a different size then the XJ650 so sadly they will not work.

 

Forgive me as I am new to the repair aspect of bikes and at my desk at work...But I have TONS of experience improving things...having said this

Would one be able to take a radiator hose of the right diameter and cut it into four lengths and re clamp those into place in Lou of the factory boots?

Would at least get you going until your wallet gets fixed. hehe

 

Re: radiator hose: Just Say No............

 

Well of course. I stated that it was an improve/mcgyver type move.
and That I am still very much a squid hehe.

 

That's too bad the xj1100 boots won't work out. It was worth a try! What do you guys recommend as the best anti seize past or spray to free up the eight bolts that are most likely frozen in place on the boots?

 

Aero kroil

 

Got some stuff called "Rescue Tape" from the hardware store. It's not sticky, but the tighter you stretch and overlap the better it fuses" itself. It's apparently air tight and water tight and has some heat resistance. Seems to be decent stuff. $10 for a 1" by 12' role.

 

Self-fusing (also called self-vulcanizing) tape is great stuff. I hadn't thought of using it to repair intake boots (which is odd since I've used it to repair a radiator hose). The specs on what I used show it to be heat tolerant up to 475ºF. The coolest (to me) feature is that once it fuses there is no seam. You can't rip it back off; it has to be cut.

 

anyone tried heatshrink tubing, this is available in most sizes,35,40,50mm and so on
you can also get it glue lined
a metre of the stuff costs around £6. 50
should make a real tight seal
stu

 

Kmoe that black tape might be Scotch 130C, good to 266F. there's also Scotch 70 self fusing silicone electrical tape good for 356 deg it has a liner and is gray.
look for them at your favorite electrical supply store.
the gray might look kind of nice

 

Well, I finally bit the bullet and purchased a new set of intake manifolds and bolts. I didn't buy the gaskets however because they were priced quite high and was intending to cut them out myself. Chacal recommends using a high performance gasket that will swell in the presence of fuel. Do you guys have recommendation for good gasket material to use?

 

Sorry to revive this again...
But.. My manifolds were cracked like crazy! I repaired them while I was waiting to find a deal on some new ones! I finally found some brand new, but I've been rocking the repaired ones for about 2 years now, without maintaining them, with no leaks or new cracks!

Here's what I did:

I lightly dremeled the cracks on the inside, bent them open, used Seal-All to fill the areas in contact with fuel, clamped, then re-sanded.

I used MXBon (www.mxbon105.com) to superglue all of the outer cracks shut, because regular super glue would probably never cut it. This stuff drys super fast and is super nasty for your nose and eyes! Wear a mask! After filling a crack, I squeezed the crack shut for about 30 seconds to a minute just to be safe. Lightly dremeled all the dried excess away, coated the whole outside with Seal-All, sanded, put on another layer of Seal-All.

I feel that the Seal-All keeps the MXBon from being affected by gas...
After about a year, before I came up on new manifolds, I had checked the insides to see if the Seal-All was getting bad... And it was in great conditon!