Intake Boot
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Thread: Intake Boot

  1. #1
    Member BC4Lyphe's Avatar
    Join Date
    Feb 2013
    So for the past couple weeks I've been slowly restoring my '87. At first I didnt mind it because of all the snow we've been getting but since the nice weather has rolled in I want to get this over with!

    I was about to order a new intake boot as mine had been repaired by the PO and it just split as I was removing the carb. $46! YEA RIGHT! So I pulled mine apart. It has been repaired using some kind of epoxy type of deal. I just put the metal tab in a nice and chipped the epoxy away with a hammer and flathead.

    Once I got it apart I could see its just a cast metal base with a rubber tube bonded to it. I chipped off the bigger pieces of epoxy and used an Xacto knife to shave everything down to bare metal. *Note To Self* Why didnt I buy myself a Dremel years ago? Could have saved a ton of time with one on this project.

    I measured everything so I could go on ebay searching for a boot off a different bike/atv. I came up with nothing.

    I think I will epoxy/weld a metal tube to the base so I can simply slip a rubber hose over it and secure either end with a hose clap. If I did this I could just replace the hose once it shrinks or gets hard over time. Of course this is harder than my other idea. Idea #2 is trying to epoxy/glue a rubber hose right to the metal. A lot simpler but not as good.

    I think you should be able to get to the folder with the rest of the pictures which I will add as I move along with the project. Here are a few dimensions for starters.

    IMG_3727 by BC4Lyphe, on Flickr

    IMG_3725 by BC4Lyphe, on Flickr

    Note- the angle of the intake is built into the metal base

    IMG_3722 by BC4Lyphe, on Flickr

    IMG_3735 by BC4Lyphe, on Flickr

    Note- the diameter of the metal intake tapers in by about 0.350"

    IMG_3733 by BC4Lyphe, on Flickr

    62mm spacing

    IMG_3729 by BC4Lyphe, on Flickr

    The familiar M6x1.0 screw holds intake to cylinder

    IMG_3728 by BC4Lyphe, on Flickr

  2. #2
    Senior Member Rainman's Avatar
    Join Date
    Jul 2010
    Ephrata, WA
    Looks like you're on the right track. Let us know what you come up with. I bit the bullet and bought a Dremel last year. It saved me tons of time and money and should have bought one years ago. Keep up the good work.
    If you can't find it, grind it

    1990 TW200

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