How to remove intake rubbers

The intake rubbers/inlet manifolds of my 1988 xj900f show some rupturing (also in the inside)
1 They seem reluctant to be removed.. does anyone have a tip?

2 When i install the replacement, should i add an paper gasket between the head and the rubber?

 

Remove the screws, know them off with a mallet. They have an o-ring for sealing against the new gaskets you install.

 

Hope you get them out without them shearing off the bolt heads.

 

So you have to get separate hat-resistant O-rings, okay.
Indeed loosening the Allen bolts seem to be the problem?

 

Lose of penetrating oil on them allen heads. Use a sharp flat strong blade to get between the two surfaces and slowly work around. If you want to reuse them, do it slow and not with so much force you will bend them and then cause air leaks when re-installed.

 

The reason why i want them off is because of ruptures, also on the inside?
Hmm so no quick repair then...
New ones are around 100 euro's. From China a lot cheaper.. did anyone dare this?

 

Some have bad experiences with Chinese boots. From falling apart to vacuum tubes falling out.

 

Does that go all the way through? If I were cheap and I am....lol, I would use a soldering iron and see if I could coaxs them back down and seal that are. That or a flat screwdriver that has been heated up with a torch. Just a thought.

 

Will it work?

 

Doesn't look leak proof to me!

 

It will be as good as the Chinesium intake stubs. I wonder if the stubs could be cut where the bolts are just to free them (without damaging the head of course) and then use a Mapp gas torch on the bolts, get them very hot before trying to remove them. Use a Dremmel or something like that. Just an idea?

 

i did exactly the same ,using 4" heat shrink tubing, but did a better job than in that video, he's overlapped it too much , i cut mine short of the mounting flange, and also used black silicone sealant ( rtv, i think you call it) around the round stub before shrinking it

 

When did you do that?

 

it was on my cafe racer build i did about 2014

 

bensalf's 4 year caferacer build | XJBikes - Yamaha XJ Motorcycle Forum

 

Oh I remember it now nice machine you did a great job of that build.

 

intake boots bit is on end of page 3

 

Do you still have the bike? Using RTV to fill the cracks and then the tube. I would do that before buying the Chinese stubs. If he uses the soldering iron as @Timbox stated and your solution that is better than snapping the bolts. Going to real your build again later. No wonder it took a long time to polish your engine cases. Great work.

 

Really, then i will think spend some money on the real thing..

 

My biggest fear when removing anything on the intake or exaust side.
I have been learning how to stick weld so that I can get them out when that happens. Now that I can stick weld, I'm certain it will NEVER Happen!

 

It is not just the bolts snapping that's bad but if the head has to be removed for a machine shop to remove them that's worse. I got the welder too.

 

yeh, thanks, i still got the bike, its hardly turned a wheel since i built it, but thats gonna change next year after i get it back on the road over winter.
been too busy building my other 2

 

sorry pictures were supposed to be thumbnail

 

Did you modify the exhaust before the silencer on the green one?

 

yes i had the middle 4 into 1 custom made, headers are original ,silencer "if you can call it that" is just a off the shelf classic silencer

i converted entire electrics to digital and LEDs all round

 

Looks good. I might convert my bike to Led one day. I was reading more about the red framed bike I did not know you could the pressure switches for the brake lights. I like the air box alteration too, how does it run with the Honda oil filter in there? Good use of the space below the seat too. Did you do the welding for the monoshock mounts and the chain guard? Looks awesome.

 

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how does it run with the Honda oil filter in there?
Did you do the welding for the monoshock mounts and the chain guard?
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it seemed to run just fine, i only did around 200 miles on it,
my brother did the welding on the frame , as the chainguard is aluminium i had to take it to a local fabricator to weld up, i did the grinding and polishing after

 

I think you will win prizes if you put your bike into shows. Great build.