Articles & photos
Guide to mount the new intake flanges.
2-7-2015 - Here is a short guide on how to mount the Twin Motorcycles developed intake flanges.
The development article can be found HERE.
NEEDED BEFORE YOU START:
- The right tools and knowledge to replace the intake seals on your Bike model
- some brake cleaner
- scotch brite / sand paper
- a round manifold (-:
First check the cylinder heads so the contact survace is clean, flat has no dents are nice and free from corrosion and dirt.
If not clean them with scotch brite carefully. if your cylinder heads are damaged by corrosion or big dents / nicks , a good seal can not be acompliced, please contact us for options or advice
Before you start. put a piece of towel or a big piece op paper in the intake to prevent dirt getting into the cylinder head.
In this example a little cleanup with scotch brite will work, clean the surface good with brake cleaner and a towel after you cleaned them.
The problem as you can see old seals, remove them and the flanges.
Check the intake runners for damage and burrs, dent's and if they are round. This is very important for a good and long lasting soution.
We notice in our workshop a lot of oval and damaged manifolds.
Also clean the intake runners with scotch brite or fine grind sand paper, check if there are any sharp edges, give the front edge a little deburring.
Clean the intake manifold very good, A can of brake cleaner will do miracles. and test fit the new flanges ( take the o-rings out ) to check if the intake manifold runners are round, and the new flanges slide on with just a little play.
you see here a manifold that was never removed, but still has a huge nick, and runners are oval
so sanded this manifold to remove the nicks and to make theme more round so the O-ring fitting would correctly seal
Our intake flanges are marked rear and front, be sure you place them in the right cylinder in the same way as the original ones.
Here you can see the rear flange
now check the flanges to the cylinder heads surface for correct fitting, we have designed the new flanges as thick as possible and they are CNC machined, but we see some times the manufactoring tolerances off the cylinder heads can be off, this can mean the flange will interfear to the edge off the flat machined surface off the cylinder head, it can be possible you need to round off the upper edge off the flanges a little more to ensure they will seat flat
notice i test here the front flange on the rear head !!
if needed the chamfered edge can be rounded some more to ensure a good flat fitting
If you have cleaned and checked and be sure the roundness of the intake runners can be confirmed, put back the o-rings and use the mounting lubrication to coat the o-rings both good, this will protect theme when mounting and hold the rings in place. We add lubrication to the box.
Press the flanges on the intake manifold, it will need some force, so the O-ring will compress for the right fitment when cold.
You should be able to position the flanges by turning, you should feel some resistance.
First screw in the 2 bolts for the U-slot. Clean the throttle body inside and be sure there is no dirt inside anymore.
Next carefully slide the manifold in to place with care.
The 2 holes on the front and rear flange should line up with the treads in the cylinder head.
Next start with the right side bolts leave some space as in the picture don't tight them complete.
Take care that the fixating hole should line up with the mounting bracket.
Now screw the 2 other bolt's on the manifold on and leave some space as seen in the picture don't tighten them.
Now slowly start tightening the flange mounting bolts and give all the same turns crosswise. Don't turn i bolt in complete but
cross wise turn them in equal at a time.
No tighten them complete so the front and rear flanges will contact the cylinder heads try to give all 4 bol'ts the same pressure before mounting them complete.
Now tighten the screws and check in your manual how to do this, TPS should be reset and checked after replacing the manifold.
Now your bike is ready for a warm up and check if they don't leak. Here is a video how to check: When all is oke. Take the bike for a test ride and to be
sure they don't leak test again when home. When they do leak you need to start this procedure all over again and take the manifold of and check for dent's
or problems in the manifold itself. This is how we learned the hard way.
Some product pictures.
! note this is a solution for bikes with continues problems with leaking intake seals,
if you don't have problems with intake seals on your bike,
please do not consider this to be a upgrade for you.
as the tollerances on your bike , cylinder head to head spacing and manifold dimentions are good !