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Inlet manifold problem - xj650

Discussion in 'XJ Technical Chat' started by Butter bean, Nov 8, 2015.

  1. Butter bean

    Butter bean New Member

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    Hi all, I was wondering if anyone could help. I'm trying to replace a split inlet manifold on carb number 4. I bought a right hand replacement and have just tried to fit it. All went fine but the problem I'm having is getting the carb end to stay in.

    It keeps slipping out until there is just a bit in the rubber manifold, almost like the manifold is just a tad to small.

    Has anyone else had a similar problem and got any tips, this has been dominating my day for something I stupidly thought would be relatively easy!!!!

    I have to confess I'm a new owner and new to tinkering with bikes so please forgive my lack of knowledge!!

    Cheers
     
    Butter bean, Nov 8, 2015
    #1
  2. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    Warm the intake boot with a hair dryer, and puuuuush. They are supposed to be a tight fit. You can use a hardwood handle as a lever to help slide the carbs back in.
     
    k-moe, Nov 8, 2015
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  3. Butter bean

    Butter bean New Member

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    Cool, will give that a go. I've only changed the one, do you think I need to loosen the others and push them all in together?
     
    Butter bean, Nov 8, 2015
    #3
  4. rocs82650

    rocs82650 Well-Known Member

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    Yes.

    Gary H.
     
    rocs82650, Nov 8, 2015
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  5. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    YES
     
    hogfiddles, Nov 8, 2015
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  6. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    How did you only change one while leaving the rest of the carbs in place?! Did you split the carb rack while it was on the bike?
     
    k-moe, Nov 8, 2015
    #6
  7. Stumplifter

    Stumplifter Well-Known Member

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    Maybe the question should be:
    What side of the carbs is this inlet manifold that which you speak of?
    Is it between the engine and the carbs or the carbs and the airbox?

    If it is the airbox side of the carbs and your airbox isn't fully forward then it may not fit/ stay in place.
     
    Stumplifter, Nov 8, 2015
    #7
  8. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Good call, stumpy..... He may be talking about the airbox-to-carb boots rather than the carb-to-manifold boots. That would make more sense....
     
    hogfiddles, Nov 8, 2015
    #8
  9. rocs82650

    rocs82650 Well-Known Member

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    It does sound strange.

    Gary H.
     
    rocs82650, Nov 8, 2015
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  10. Butter bean

    Butter bean New Member

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    I Didn't split the carb rack, there was enough space. The old one was split so it was easy to get off and then there was loads of room to get the marigold in between the carb and the engine, so much so I'm now struggling to get them not to split apart!
     
    Butter bean, Nov 10, 2015
    #10
  11. Butter bean

    Butter bean New Member

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    Hi - it's the carb to engine side
     
    Butter bean, Nov 10, 2015
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  12. Butter bean

    Butter bean New Member

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    The hardwood lever worked a treat, managed to get a real nice fit and all worked great but on my ride in this morning it popped back out!
     
    Butter bean, Nov 10, 2015
    #12
  13. Butter bean

    Butter bean New Member

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    image.jpeg image.jpeg Hi all, I've attached a couple of photos to show my struggles!

    Thanks to everyone for the advice and comments, it's really appreciated as I'm pretty clueless (as I'm sure you can tell!!)
     
    Butter bean, Nov 10, 2015
    #13
  14. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    You don't have them in all the way (as I think you already know). The groove in the carb body interlocks with a ridge in the boot. You also need to have narrower clamps that drop into the outer groove on the boots so the clamp can tighten down on the inner ridge and lock the carb into place. Thirdly you should fabricate a bracket to support the rear of the carb bodies. Without the support from the airbox the carbs can work loose again.
     
    k-moe, Nov 10, 2015
    #14
    rocs82650 and Stumplifter like this.
  15. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    If they popped out again, you DIDN'T manage to ge a real nice fit.....
     
    hogfiddles, Nov 10, 2015
    #15
  16. quebecois59

    quebecois59 Well-Known Member

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    Is it possible the "new" intake boot isn't the right one for your bike? Where does it come from?
     
    quebecois59, Nov 11, 2015
    #16
  17. Butter bean

    Butter bean New Member

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    Hi k-moe - thanks for the tips - I've tried a smaller clamp, got the fit very tight and loosened all the others but it immediately slips back out. Am starting to worry I've got the wrong one. I think I might need to change all of them as something certainly isn't right. Cheers for the advice and help.
     
    Butter bean, Nov 16, 2015
    #17
  18. Butter bean

    Butter bean New Member

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    Butter bean, Nov 16, 2015
    #18
  19. quebecois59

    quebecois59 Well-Known Member

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    It is possible you got the wrong one even if you ordered the right one.
     
    quebecois59, Nov 16, 2015
    #19
  20. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    How come it it never works in reverse?.... Order the wrong part but get the RIGHT one?
     
    hogfiddles, Nov 16, 2015
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  21. rocs82650

    rocs82650 Well-Known Member

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    It does if you order from Len.;)

    Gary H.
     
    rocs82650, Nov 16, 2015
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  22. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Ok-- you got me there... i cant argue that at all :). I concede....

    Dave F
     
    hogfiddles, Nov 16, 2015
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  23. rocs82650

    rocs82650 Well-Known Member

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    Lol.

    Gary H.
     
    rocs82650, Nov 16, 2015
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  24. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    I can't quite make out the valve cover type. Does yours say YICS on it?
     
    k-moe, Nov 16, 2015
    #24
  25. Butter bean

    Butter bean New Member

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    So - I bit the bullet and have replaced all 4 manifolds - what a nightmare getting the carb body pushed into the boots!!!!! I tried brute force, lumps of wood and 2 mates and still struggled!

    In the end I used a ratchet strap and they finally popped in!!!!!!!!!

    Happy days, all done!

    Cheers for everyone's help - this forum is an amazing resource and all your help is grately appreciated.

    Cheers all.
     
    Butter bean, Nov 22, 2015
    #25
  26. Butter bean

    Butter bean New Member

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    Hi K-moe - yep, it's a yics
     
    Butter bean, Nov 22, 2015
    #26
  27. hogfiddles

    hogfiddles XJ-Wizard, Host-Central NY Carb Clinic Moderator Premium Member

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    Did you try a smear of Vaseline, and a hot air function warm the boots? I just push them right in.
     
    hogfiddles, Nov 22, 2015
    #27

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