Rayjay wrote:
Doc,

Do the stock manifolds go bad and leak???

Do you know how much the Nemesis manifolds run?

Rayjay

They leak but usually at the joints and sometimes it's difficult to seal. When you put it back on you need to make sure you tighten all four bolts evenly or the manifold will distort.

I believe they were about 130 but phone Doug up and ask.

You may have more than one thing going on but my impression was the it was worse on one cylinder so that may mean an air leak. I assume that you plugs and coil are OK.

Doc

Thanks Frank. I hope so too

Doc,
I swapped coils and checked plugs, did compression test, trouble-shot the ignition system (replaced pickup coil),etc. It seems that everything I do helps some, but there is a definite leak that wakes up when the engine heats up -- (that may be a tell-tale sign). I put on larger *O* rings and make sure I tightened everything down evenly and fully. I tried to fully tighten the rear cylinder first and then the front. I don't want to over-tighten and strip out my threads.

Unless there's a way for air to enter above the manifold, it is definitely the flange leaking. It gives one "H E double toothpicks" of a vibration at about 60 and above, not to mention the distinct popping exhaust sound from the rear exhaust pipe.

In reading from the Mikuni website, I found out that the leaner air can produce a detonation problem. I think I have it. I just want to be sure that a new manifold will cure this UNLESS there's another way to install the one I have. I don't want to spend $$ on things that won't help me solve this.

I wanna ride my scoot!! ....

Rayjay

While pondering my situation with the leaking manifold last night, it occurred to me that I could over-torque the flange bolts on the intake. I figure that may distort the flanges over the *O* ring (acting like a fulcrum) and cause the center areas top and/or botom to open up.

Although this does not help to understand why this had started in the first place. I bought the bike from my brother-in-law who said he never had any trouble. If I remember correctly, it vibrated on me from the start once I got to ridin' her.

Does this line of reasoning make sense??

I will attempt one more leak fix per to my above thinking before I order a new *carb joint*

Rayjay

I'm beginning to eat, sleep and dream this stuff!!!

Breaking News:

I went home for *lunch* and worked on my Black Beauty. I removed the manifold, checked the new over-sized *O* rings and wiped the head clean. I re-installed the manifold very carefully. Finger-tightened the bolts, then 1/2 turned each one until tight and gave a slight 1/4 turn more.

Took her out and short-rided her. Still had vibration even though lower speeds and some RPMs were smooth as I would like. Came back and sprayed carb cleaner onto the flanges to find still leaking. Also sprayed the flange/pipe joint where black rubber was cracking and heard RPMs drop. I think this one has bitten the dust.

I emailed about a Nemesis manifold = $150 + shipping. Only $15 more than new *hand-ported* stock manifold from Phat. DK also said that if I buy the Nemesis coils ($130), I would save about $7 shipping. I'll go for both as long as I can fit my stock carb on the Nemesis.

I just hope there is no other damage or issues once I install the new manifold.

Thanks for bearing up with me, but it's good to at least air my *saga* with yuse guys...

Rayjay

BTW -- Ordered floorboard extenders from Billjr so I must be feeling better about my perceived progress. I'm about 17 1/2" taller than Musky and I need all the room I can get.

One last attempt to get the stock manifold to seal before I buy a replacement:

I installed NAPA self-adhering (one side) gasket material I cut out onto the flange areas. I eliminated the *O* rings and will take a test drive in a few. (Rained last night.)

Rayjay

EDIT FOLLOW-UP: Went out for test and no change after engine heated up. I tightened flange bolts down more and it seemed to get worse -- heat could have exacerbated it. Cold - runs good. Dealer parts guys suggested exhaust leak at gasket and I will check. Could be that the manifold distorts when hot.

Just a quick update from the original post. The weather has cooled down significantly in Texas now and the top end chatter is all but gone. As I began to suspect as time went by, the top end chatter seems to increase with the outside temperature. I bought the bike in the fall and never had too much engine noise in the begining. As things "seemed' to get worse the temperature was warming up in Texas as well. I'm pretty much back to the overall sound the bike had in the very begining. And that's alright with me.

With more time on the bike I'm much more comfortable with the issue. 6000 trouble free miles. I hope this helps those who are as concerned as I was.

Ride Safe,

DRW

Drw, if makes you feel any better, my '07 also is a real chatterbox in warm weather. My old Harleys used to do the same thing. In hot weather, my Electra Glide used to sound like the pistons were swapping cylinders. The Road* isn't quite that bad but it's still noisy. Still, it runs like a scalded dog! That intake leak is a horse of a different color though. Did you ever get that squared away?

Thanks for the feedback stinger. Good to hear other perspectives. My previous bikes were water cooled and this one had me worried for a while.

The manifold issue was Rayjay and I'm not sure what happened.

Thanks

DRW

I stumbled on a thread about SVS while grieving over my bike and determined that was my problem. I treated the scoot with Seafoam in the gas and sprayed Seafoam Deep Creep into exhaust ports and onto piston tops through spark plug holes. I installed an new Nemesis intake manifold and it has been running great ever since.

Just a little update on the original post. The chatter still remains and deffinately gets worse as the temperature rises. But the bike has been flawless from a reliability standpoint. It's just very annoying. Went around the corner and fianlly decided to test ride a new Road King. Pretty impressive but pricey. There some engine noise but not nearly as metallic as the Road Star. I then stopped into my favorite Star dealer and got to talking. He talked me into a Roadliner test ride. Wow! What a motor! I couldn't get it to chatter at all. I think the oil cooler and counter balancer really helped lower any chatter from that bad boy. Now it's got me thinking!