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1Back to top Go down    Manifold rubber on Wed Mar 26, 2014 4:21 am

nino


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Gday all, its time to change rubber boots on inlet an I have some simple questions:

1. Is there enough space between cylinder head and frame to move plenum andthrottle body and mount new rubber?

2. Any special tips, tricks about it like heating, lubing etc?

Thanks in advance

    

2Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 5:20 am

charlie99

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its almost impossiblewithout taking off the plenum and tank nino

then the throttle bodies to get to the head fitting ones

don't forget to seal the head flange gaskets with a little diebond 1209 sealant ...and let it go off for a while before fitting, do not over tighten the retaining screws

I have also noticed that there is a little ridge along the bottom of those rubbers (made to position to the head ?) that I removed on mine to get a good seal .

don't forget to position the head fitting rubbers central to the inlet port ...not just the way that they seem to fit ....test with your finger how much clearance is around the fitting of the runners to the port ...as a few tenths of a millimetreout could make a great difference to the performance of the engine
not so good



better



I would advise to use some lubrication on the rubbers when trying to refit them up also

there is a ridge built into the castings of the throttle bodies upper and lowers that adds additional complication and restricts easy fitting





good luck ! and hope it solves some issues for you

cheers


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3Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 5:47 am

nino


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@charlie99 wrote:its almost impossiblewithout taking off the plenum and tank nino

then the throttle bodies to get to the head fitting ones

don't forget to seal the head flange gaskets with a little diebond 1209 sealant ...and let it go off for a while before fitting, do not over tighten the retaining screws

I have also noticed that there is a little ridge along the bottom of those rubbers (made to position to the head ?) that I removed on mine to get a good seal .

don't forget to position the head fitting rubbers central to the inlet port ...not just the way that they seem to fit ....test with your finger how much clearance is around the fitting of the runners to the port ...as a few tenths of a millimetreout could make a great difference to the performance of the engine
not so good



better



I would advise to use some lubrication on the rubbers when trying to refit them up also

there is a ridge built into the castings of the throttle bodies upper and lowers that adds additional complication and restricts easy fitting





good luck ! and hope it solves some issues for you

cheers

Thanks Charlie. What kind of clamps to use?

    

4Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 5:56 am

Guest


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I managed to change all of mine without removing much. The top rubbers come off the throttle bodies quite easily and then the bank of bodies comes off in one piece. I used a smear of silicone grease on mine where the rubbers touch metal - the RAF taught me that.
The throttle bodies were then balanced, I took my time with this bit, and the bike was transformed.
Mine is a 16v, not sure if the job is much different.

    

5Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 6:04 am

charlie99

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hi nino

have a look though the forum
there is the part numbers for the Suzuki clamps ...which are adjustable and re-useable

don't have the link at this moment ...sorry ..ill have a look though

I have had the adjustable ones on the lowers ...but haven't yet bought the ones for the uppers

(pst ...I just opened up the top clamps with circlip pliers to expand at the crush point ...then after refit closed them up again for a good seal ...if you use the real octeker pliers for the clamping theybecome acut offjob as the creases in the metal make Itnearly impossible to expand the clamps with out metal fatigue and breakage - failure )
seal them up with a good set of side cutters



Last edited by charlie99 on Wed Mar 26, 2014 6:08 am; edited 1 time in total


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6Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 6:04 am

RicK G

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bikerboy wrote:I managed to change all of mine without removing much. The top rubbers come off the throttle bodies quite easily and then the bank of bodies comes off in one piece. I used a smear of silicone grease on mine where the rubbers touch metal - the RAF taught me that.
The throttle bodies were then balanced, I took my time with this bit, and the bike was transformed.
Mine is a 16v, not sure if the job is much different.
The 16v have an O-ring and the 8v don't have one so you have to use sealant and it is awkward getting enough room to do the sealant properly.


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats." from Mencken's 1919 Prejudices

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7Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 6:20 am

charlie99

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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
    

8Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 7:41 am

nino


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Rick, you wrote that earlier K 8 Vdoesnt use O ring on head. Are you shure cause my part supplier told that I need O rings

    

9Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 7:49 am

Guest


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Chris Harris uses alcohol as a lubricant to jam Throttle Bodies into rubbers in his videos. Alcohol as in rubbing alcohol not whiskey SmileIt evaporates.

    

10Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 7:53 am

RicK G

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Yep quite sure


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"Every normal man must be tempted, at times, to spit upon his hands, hoist the black flag, and begin slitting throats." from Mencken's 1919 Prejudices

Bikes 1993 K1100 LT, 1998 K1100 LT, 1993 K75 RT, 1996 K75RT, 1986 K75 GS, 1979 Z1300 Kawasaki X 2 for now
    

11Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 8:05 am

charlie99

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confirmed nino

no oring in there

there is what looks like a relief for an oring but nada


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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
    

12Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 8:44 am

robmack

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@charlie99 wrote:have a look though the forum
there is the part numbers for the Suzuki clamps ...which are adjustable and re-useable
48mm Suzuki band clamp 09402-48208 for TB->bushings and bushings->air plenum connections. Cost about$4.75 each.


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13Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 2:38 pm

brickrider

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When you use the hose clamps (suzuki or others) it's a bit fiddly to position them so the worm drive bit doesn't foul the movement of the TB arm. There is not much room for error there.

    

14Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 3:46 pm

duck

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When doing this, be careful not to knock the TPS out of position so that it holds the throttle open - and then spend the next hour trying to figure out why the bike wants to idle at 6000 RPM. (DAMHIK)


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86 Custom K100 (standard fairing, K75 Belly pan, Ceramic chromed engine covers, paralever)
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15Back to top Go down    Re: Manifold rubber on Wed Mar 26, 2014 5:15 pm

Speedaddictedberk

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Positioning the clamps is best done while opening and closing the throttle repeatedly. It's annoying if like me you struggle when things don't line up but I couldn't get them all the same and still be able to do up the clamps.

Although it's more annoying when you find out you can't open the throttle because a clamp is blocking it.

http://leportphotographic.co.uk
    

16Back to top Go down    Re: Manifold rubber on Thu Mar 27, 2014 1:29 pm

nino


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Thanks for quickanswering. Anybody know what is insidediameter of manifold rubber? Is it same on both sides? Or what is outer diameter of thr. bodies in place where rubber sits?

Regards

    

17Back to top Go down    Re: Manifold rubber on Thu Mar 27, 2014 2:07 pm

charlie99

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40.10 mm od round about ...top and bottom of the throttle bodies nino
don't forget the ridge of about .5 mm about 4.5 - 5mm from the top

39.78 mm for the bottom rubbers id tb end
31.5 mm id on the head rubbers measuring the rubber as it connects to the head

the top rubbers measure 42.00 mm and 39.2 mm id

these are old rubbers ...so may have changed from new ...slightly


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cheezy grin whilst riding, kinda bloke ....oh the joy !!!! ...... ( brick aviator )

'86 K100 RT..#0090401 ..."Gerty" ( Gertrude Von Clickandshift ) --------O%O
    

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