intake manifold construction

[RS Thornton]

I'm putting this here and in other bikes, just hoping to find someone with the answer.

How do you bond the rubber part of the carb holder to the metal part?

I did not notice before but the carb holders have a metal part and a rubber part. I am trying to figure out if you can separate them and then reconnect them. If I can do this it might be possible to mount a different set of carbs on my royal star. I would take the rubber part that fits the carb and connect to the metal part that matches the head. Any ideas?

[DiverRay]

The rubbeer is "bonded" to the aluminum. It is NOT a home project you can do.
You can probably do it another way, though. If you can build the metal manifold plates to bolt up to the head, and have a short metal tube of the proper outside diameter, the same as the outside of the carb, use a short rubber hose or tube to complete. That would probably be the easiest way to make a new intake manifold.
Ray

[RS Thornton]

thanks,
It was worth a try, I've been into the machine shop and we are going to try to make a set. There are at least 2 other guys looking for the parts, so we may get a decent price at making up aluminum set and use a piece of rubber for final run.

I should not have been surprised at the clever way Yamaha changed just enough details that the 99 venture carbs will not fit on the 99 royal star without getting a custom part.

[Pat Kelly]

Maybe try the intake rubbers of an XS750 or 850. They use a rubber sleeve and 2 clamps instead of the bonded unit the 1100's have. Carbs are the same (just 3 of them instead of 4).

[RS Thornton]

That is a great idea, I will check into other bikes using a rubber sleeve, it could cut down on the fabrication work, thanks!
Any chance you know the carb size? Any chance anyone knows of any other bike using 32mm carbs?

[jetmechmarty]

Late model XS650's use the same 32 mm carbs. Look at the last item on this page:

http://www.mikesxs.net/mikesxs_parts.php?category_id=4

Easiest solution is here:

http://www.partsnmore.net/item_index...art_unique=546

[RS Thornton]

Sorry to be picky, but the carb holder for the following looks like what I need:

Fits XS750 (77-79), XS750S (77-79), XS850 (80-81), XS850L (80-81), XS850S (80-81)
High Quality - Made in Japan
OEM Reference # 2F3-13586-01-00

Anyone know what size carbs on one these bikes?
the part for the XS650 has that manifold mounting plate (as seen at Mikes XS), it looks like the XS750's used a hollow rubber tube (as seen at Partnmore). I can have custom part made that transitions from the head to a round and then make final connection with these tubes.

I feel like I am soo close, thanks for the tips

[Pat Kelly]

I've posted a query with the XSperts on the triple site as to carb sizes. I'll post the reply back here.

[Pat Kelly]

I got only one reply on the triple site. He said they are the same size (34mm?).
I was hoping for more response but I'm thinking that no one chimed in to say otherwise then they are indeed the same.

[RS Thornton]

thanks, 32's or 34's?
any chance you have an old carb holder sitting around that you could check ID, OD and length. Not going to do much with this for the next week and a half except maybe some more net surfing to see what I can find. The temp is expected to drop as low as -5 here in Michigan over the holidays. The heater in the garage was not sized for this!
Thanks for the help and have a Merry Christmas, maybe take a ride for me.
Scott

[srq68]

I have spare rubber boots off an 850, I'll check the ID and let you know soon....