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How to clean the intake manifold/boots?

Discussion in 'XJ Technical Chat' started by Oblivion, May 17, 2006.

  1. Oblivion

    Oblivion Active Member

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    I mentioned in another thread that I pulled my carbs again and took off the intake boots as well. Two of the gaskets were hosed and may have been the cause of my idle woes. I got the new gaskets yesterday, but I'm wondering how to clean the cruft off both the boots and the manifold face. I'd think carb cleaner or the like would be OK for the metal side, but don't want to use it on the rubber boots.

    If you want to see some slightly out-of-focus shots of the crud: http://flickr.com/photos/oblivion/tags/intake/

    Any suggestions? Any absolute no-nos?

    Also, while I had the carbs off again, I was going to be a good boy and take the carb bowls off and make sure all the gunk is out of there (my previous cleanings were incomplete - just sprayed what I could reach from the outside or tops and ran Sea Foam through the bowls). However after removing the 4 screws holding the first bowl, I could not get it to come off. I didn't want to pry too hard or break out the rubber mallet, so any tricks to get those suckers loose? I'm assuming my gaskets will be shot if I do get them apart.

    Thanks again.
     
  2. Robert

    Robert Active Member

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    Castrol SuperClean works wonders and won't harm the rubber. Do not use brake cleaner if you can help it. I would suggest using a screwdriver as a scraper and manually remove as much of the crud as you can using a vaccum cleaner.
    I use the handle of my screwdriver to gently tap the bowls loose.
     
  3. Oblivion

    Oblivion Active Member

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    No brake cleaner - check.

    I'm so confused by al lthe different solvents - use this on this, but for god sake not on that. This can be used on that as long as the moon isn't full. You can use this, as long as you don't care if your gaskets actually seal. I need a pharmacist for my motorcycle!

    BTW, I tried rapping on the bowls w/ a rubberized screwdriver handle. No dice. I'll be a little more persuasive tonight.
     
  4. Oblivion

    Oblivion Active Member

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    BTW, anyone know what those bolts should be torqued to. Seems like it should be pretty tight for a good seal, but I snapped one of those little buggers off tonight putting them back on. Luckily there was enough of a nub sticking out from the hole to grab on with needle nose pliers and back out the remains. I wasn't really cranking that bolt that hard, so maybe it was just fatigued - I don't know. I'm thinking I'll pick up a whole new set of 8 tomorrow, even though 6 are already in.

    Ugh.
     
  5. Robert

    Robert Active Member

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    My screwdriver handle is a dense plastic, like a plastic tipped hammer. Your lament is common, I've had to do a bit of research on the chemicals I use as well. Thank heavens for MSDS's and user support for the nuclear waste I use.
     
  6. Oblivion

    Oblivion Active Member

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    More and more I'm thinking the answer to all of my problems is a new bike. . . .


    Nuclear waste you say?

    So, no input on the torque question? I expect you to know everything, Robert ;)
     
  7. Robert

    Robert Active Member

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    New bike? They making new XJ's?
    The Haynes manual doesn't specify so I'm going to offer my best guess reply. Your carb bowl torque should be very light, about 3 ft/lbs. I'm going to suggest ('cause I know not everyone has a calibrated screwdriver) the use of a cordless drill. I've used my Craftsman cordless drill and set the torque value at it's lightest setting with good results. I'm a bit anal too, I use anti-seize on my screws as well (steel fasteners in aluminum beg for this stuff to keep them from sticking). I do happen to have 3 extra calibrated screwdrivers (very limited use for these, not too many people need them) that I'm not in need of should anyone care to relieve me of one or all ($35 each + S/H, not bad).
    Please don't burden me with these great expectations Eblo, I'm only human, I might fall a little short most of the time. I'm flattered just the same. Hope your issues are handled in short order.
     
  8. Oblivion

    Oblivion Active Member

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    Robert, I think I confused you. For the torque settings, I was asking about the intake boots screwed to the manifold. For the time being, I've given up on the float bowls.
     
  9. Nick

    Nick Member

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    exhaust pipe nuts (m6-p1.0) torque to 5.4 ft-lbs
    can't find anything on the intake?
    general info says 6mm bolt 4.5 ft-lbs
    8mm bolt 11 ft-lbs
     
  10. Robert

    Robert Active Member

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    Thanks Nick. Yes, Eblo, I was confused. Sorry. Hope you nail it.
     
  11. Oblivion

    Oblivion Active Member

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    Thanks guys. I'll use the genaric numbers - didn't break any more today.

    FYI, I got the float bowls off. Rubber mallet was required. I was going to leave them, but on the last draining, there was WAY too much cruft coming out, so I decided to press on. The bowls are NASTY caked with gunk. Unfortunately, though all parts look good, two of the gaskets are shot. I was just going to go ahead and replace them all.

    Anyone know if I can find just the gaskets, or do I need to buy complete rebuild kits? OEM sites say the gaskets are discontinued and OldBikeBarn.com doesn't seem to have them separate from a full kit.

    Thanks for any suggestions.
     
  12. Nick

    Nick Member

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    I bought some gasket material and cut my own!
     
  13. Oblivion

    Oblivion Active Member

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    Now there's an idea. General auto parts store I imagine?
     
  14. dcmilkwagon

    dcmilkwagon Member

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    That's what I did too, traced them, cut them, then I dipped them in clean motor oil before I installed them. Learned this trick from an old farmer one time, he said its better for a bowl gasket to be soaked with oil, than to let it soak up gas and start leaking. I've used this trick for over 30 years now, haven't had a problem yet. :D
     
  15. Oblivion

    Oblivion Active Member

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    Do I want fiber or cork gasket material?
     
  16. dcmilkwagon

    dcmilkwagon Member

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    I would use fiber in this case. Only because your enrichment tubes need to be at the proper depth in the fuel bowl, but then again I may be way out in left field on this one.
     
  17. Robert

    Robert Active Member

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    I would recommend the thicker fiber but cork will work ok too. Either way, their a pain in the patoot to cut out, make sure you have a hole punch (for sharp corners and starting holes), a gasket punch set (see Harbor Freight), a pair of curved nail scissors, a small ruler (for a guide when cutting and drawing lines), a mechanical pencil preferably with 0.7 lead (for outlining), a hobby knife (some folks call this an Xacto), a small ball peen hammer (to tap the gasket impression), and a pair of good old fashioned straight scissors. Why all this stuff you ask? I've been making my gaskets for years and it is all the tools I've ever needed. I would place the material underneath the bowl on a hard surface (slab of marble or thick glass) and tap the bowl to get my impression. You might want to make a master and then transfer the image onto the material to make subsequent gaskets without all the tapping (time saver, oh and I would want a copy of your pattern). Good luck bud, you've got your work "cut out" for you.
     
  18. Nick

    Nick Member

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    I used the fiber, approx same thickness as original, rated for fuel.

    Robert, why do you have to make things so complicated?

    I just used an old gasket, a pen, a razor knife, and a hole punch.
    Traced them, cut them, hole punch the screw holes, and done!
     
  19. Robert

    Robert Active Member

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    I've a complicated mind, it gets me into more trouble than it's worth sometimes. I'd be happy if I had an old gasket to use half the time. Sometimes it just isn't in the cards. I'm just picky about the gasket turning out exactly like the original even when it wouldn't matter one bit. Little anal retentive but I'm learning to let some things slide, one step at a time, I'll get there.
     
  20. Nick

    Nick Member

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    Sorry Robert, I just had to ask!
    I've been labeled anal many times myself, I can relate.
     

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