Coolant manifold

[Tat2demon]

Any tips on removing the manifold to replace the orings? I pulled the two bolts out but it seems to be pretty solid. Just want to make sure I dont mess something up without checking with you guys.

[Chris near Kansas City]

Go slow. I have used a wood block to help the process.

[Tat2demon]

Do you use that behind the manifold and pry it out or put it behind the back corner and tap with a hammer or something else?

[HMB Don]

do not use any hammers, just apply steady pressure with the long piece of woody. Pry one side then move to the other side.

[Tat2demon]

Great. Will give it a shot tomorrow.

[doug of so fla]

Make sure you clean the ports (shiney spotless clean!!!) and the tubes that insert into them) grease (green 3M pump grease works well) up the o-rings real good and install ALL pipes evenly & carefully at the same time or it will leak. The type of o-rings used on the water pump and manifold are REAL FRAGILE!! We need photos or your completed project or it never happend!!! lol!!

[Gator Mike]

when I changed mine Carl Leo suggested soaking it the night before and then using wood to pry gently on both sides back and forth. It came out fairly easy. As said before, clean it well then use lubricant to reinstall. Good luck.........Gator Mike

[96desertXII]

Good info....I will be doing this in the next few months along with all ne hoses and T-stat.

[metric]

I have to change my too, do I have to take the exhaust off to get to the manifold?

[Tat2demon]

I saw it mentioned somewhere that you dont need to but I popped mine of anyway. Seemed it would be a lot easier and taking off the exhaust is pretty simple.

[Chris near Kansas City]

While the removal and installation of the radiator can be fussy, I still prefer to have it off and out of the way when doing the manifold o-rings. I use liquid hand soap around the ring and inside the ports.

[Lance McCaw]

Just did mine on my 1987. Its not that hard as long as you are patient. Yes the exhaust has to be dropped. I try to only swivel the pipes down but not enough room so i just used my floor jack and slowly lowered my exhaust. To installed the manifold I put a very light coat of grease on rings and barely start them in. then just started tighten the 2 mount bolts back and forth gently and my went right in. Not a big deal to me but I have worked on bikes for 30 plus years.

[Tat2demon]

We need photos or your completed project or it never happend!!! lol!!

Well I forgot to get a pic of it put back in but here it is taken out! I used the handle of my carb cleaning brush to work it out. Wasnt too bad. The old orings fell apart when I took them off.

[96desertXII]

We need photos or your completed project or it never happend!!! lol!!

Well I forgot to get a pic of it put back in but here it is taken out! I used the handle of my carb cleaning brush to work it out. Wasnt too bad. The old orings fell apart when I took them off.

So the o-rings go into the dimples on the pipe?

[Tat2demon]

Yep. I had to try putting it back on twice. One of them wasnt greased enough and started to push out of the groove.

[Tat2demon]

Oh and make sure you use a wire brush or something and clean up the ends real nice. They were pretty crusty.

[96desertXII]

Will be doing this after I move. Right now I get a few drips after it sits for a couple of days without riding it, but being in southern California, I ride all the time.

[Tat2demon]

Mine wasnt bad but I figured since I would have thr front off the bike to get the radio out I may as well do everything I can up there.

When you put it back in make sure to go slow and keep checking all the way around all four ports several times to make sure the rings arent being pushed out. I did a couple turns of each mounting bolt, check with a flashlight, couple more turns, check ect.

[96desertXII]

I will do that, along with the changing of the hoses, there a little stiff now. I will change the carbs out for the rebuilt set that I have also, along with some other repair/upgrades that need to be done.