Motorcycle and Small Engine Servicing LO2: Intake Manifold and Exhaust System INTRODUCTION The intake manifold and exhaust system are two of the most critical components of a motorcycle’s engine system, working in tandem to deliver air and fuel to the combustion chamber and then expel the resulting exhaust gases. These systems play a crucial role in determining the engine's performance, including its power output, fuel efficiency, and overall responsiveness. The intake manifold is responsible for delivering the air/fuel mixture to the engine's cylinders, where it is ignited to produce power. The design and construction of the intake manifold can significantly impact the engine's performance, including the engine's responsiveness and power output. The exhaust system is equally critical, responsible for expelling the exhaust gases from the engine after combustion. The design and construction of the exhaust system can impact the engine's overall performance, including its power output, fuel efficiency, and sound characteristics.Whatis intake manifold An intake manifold is a component in an internal combustion engine that connects the air intake system (usually a carburetor or fuel injection system) to the engine's cylinders. Its primary functionis to distibute the air and fuel mixture to the engine's combustion chambers evenly. The design and construction of the intake manifold can significantly impact the engine's performance, including its power output, fuel efficiency, and overall responsiveness.Intake Manifold Parts (1) Intake manifold (2) Flanges (2) Rubber seals @) SpacersTypes of Intake Manifolds There are two main types of intake manifolds: stock and aftermarket. Stock intake manifolds are installed by the manufacturer and are designed for general use. Aftermarket intake mani specific applications and are often made of higher quality materials. They can provide better air flow and increase performance.Factors Affecting Intake Manifold Performance There are several factors that can affect the performance of your intake manifold. These include the size and shape of the manifold, the length and diameter of the runners, and the material used to make the manifold. It is important to consider these factors when choosing an intake manifold or optimizing your current one.Tips for Optimizing your Intake Manifold Here are some tips for optimizing your Intake manifold: 1) Use a larger diameter manifold to increase air flow. 2) Use shorter and larger diameter runners to increase velocity. 3) Smooth out any rough surfaces to reduce air flow turbulence. 4) Choose a material with good thermal conductivity and low waight. 5) Use a custom-designed manifold for your specific motorcycle mode!What is Exhaust Manifold An exhaust manifold is a component in an internal combustion engine that connects the engine's cylinders to the exhaust system's piping. Its primary function is to collect the exhaust gases from the engine's cylinders and direct them into the exhaust system's piping to be expelled from the vehicle. Exhaust manifolds are typically made of cast iron or stainless steel and are designed to withstand high temperatures and pressure. The design and construction of the exhaust manifold can significantly impact the engine's performance, including its power output, fuel efficiency, and sound characteristics. HONDA WAVE 125 STOCK PIPEExhaust manifold Parts us 1\Header: The section of the exhaust manifold that attaches to the engine and collects the exhaust gases from each cylinder. 2.Primary tubes: Tubes that extend from the header and connect to the collector. 3.Collector: A section of the exhaust manifold where the primary tubes converge into a single pipe. 4.Secondary tubes/Muffler: The single pipe that exits the collector and carries the exhaust gases out of the motorcycle. S.Heat shields: Protective covers that are placed over sections of the exhaust manifold to protect riders from coming into contact with hot surfaces.Types of exhaust manifold 1.) Stock exhaust manifold: The original equipment exhaust manifold that comes with the motorcycle from the manufacturer2.) Performance exhaust manifold: Aftermarket exhaust manifold designed to improve the engine's power output, sound, and overall performance. These can be made of stainless steel, titanium, or other high-performance materials and often have a tubular or tri-Y design.3.) Custom exhaust manifold: Exhaust | ¥ manifold that is designed and fabricated specifically for a custom-built motorcycle. These can be made from a variety of materials, including steel, aluminum, or titanium, and can be designed to improve power output, sound, and aesthetics.Effect of bad exhaust manifold 1.Reduced power and acceleration: A damaged or clogged exhaust manifold can restrict the flow of exhaust gases, leading to reduced power outputand slower acceleration 2.Increased fuel consumption: When the exhaust manifold is not functioning correctly, the engine may have to work harder to expel exhaust gases, leading to increased fuel consumption. 3.Loud or unusual noises: A damaged or cracked exhaust manifold can cause loud or unusual noises that can be annoying, distracting, and potentially harmful to the rider's hearing 4.Environmental impact: A bad exhaust manifold system can release harmful pollutants into the environment, contributing to air pollution and negatively impacting the rider's health and the community's well-being. 5.Safety hazards: A damaged exhaust manifold can also pose safety hazards, such as the Potential for exhaust leaks, which can lead to the release of toxic gases into the rider's cabin and can cause health problems, includingheadaches, nausea, and dizziness,Whatis Motorcycle Muffler A motorcycle muffler, also known as a silencer, is a component of the exhaust system that is designed to reduce the noise produced by the motorcycle's engine. The muffler is essentially a hollow metal container that contains sound- absorbing materials, such as fiberglass or steel wool, that help reduce the Noise produced by the engine as the exhaust gases flow through it The muffler is an important component of a motorcycie’s exhaust system because it not only reduces the noise produced by the engine but also helps contro! emissions by reducing harmful pollutants that are released into the environment.Parts of Motorcycle Muffler The basic parts of a typical muffler include’ Inlet pipe: This is the pipe that connects the mufflerto the exhaust header of the motorcycle, 2.0uter casing: The outer casing is the metal shell that encloses the muffler'sinternal components. 3.Baffles: Baffles are metal plates or tubes that are placed inside the muffler's casing to create a series of chambers that help reduce the noise produced by the engine, 4.Sound-absorbing materials: The muffler’s sound-absorbing materials, such as fiberglass or steel wool, help to reduce the noise produced by the engine as exhaust gases, flow through it. 5.Outlet pipe: This is the pipe that connects the muffler to the tailpipe of the motorcycle 6.Mounting brackets: These are metal brackets that are used to attach the muffierto the motorcycle's frame or chassis.Service Maintenance of Motorcycle Muffler Here are some maintenance tips for a motorcycle muffler: 1.Regular inspection: Check the muffler regularly for signs of damage, such as cracks, rust, or holes. These can affect the muffler’s performance and cause excessive noise and emissions. 2.Cleaning: Clean the muffler regularly to remove dirt, debris, and other contaminants that can clog the internal components and reduce its effectiveness. Use a mild detergent and a soft-bristled brush to clean the outer casing and inlet and outlet pipes. 3.Replacement of sound-absorbing materials: The sound-absorbing materials inside the muffler can deteriorate over time, reducing its effectiveness. It is important to replace these materials periodically, depending on the manufacturer's recommendations. 4.Avold harsh chemicals: Avoid using harsh chemicals or solvents when cleaning the muffler, as these can damage the muffler’s components and reduce its effectiveness. 5.Professional inspection: If you notice any unusual noises or emissions from the muffler, have it inspected by a professional mechanic. They can diagnose any problems and recommend repairs or replacements as necessary.Service Maintenance of Exhaust Manifold 1.Regular Inspection: Inspect the exhaust manifold for signs of damage or cracks, including rust, corrosion, or holes. 2.Clean the exhaust manifold: Remove any debris or dirt buildup from the exhaust manifold regularly. Use a soft-bristied brush to remove any debris or dirt that may have accumulated on the manifold. 3.Check the gaskets: Inspect the gaskets between the exhaust manifold and the engine or the exhaust system for wear or damage. Replace any gaskets that are damaged or worn 4.Fix any leaks: if you detect any exhaust leaks, have them repaired immediately. Exhaust leaks can be hazardous to your health and the environment 5.Lubricate the flanges: Lubricate the flanges that connect the exhaust manifold to the engine or exhaust system with anti-seize lubricant to prevent corrosion and facilitate removal. 6.Use high-quality replacement parts: If any components of the exhaust manifold need to be replaced, use high-quality replacement parts that are designed for your motorcycle's make and model.Motorcycle Intake/Exhaust Manifold Service and Maintenance Tools Here are some of the tools you might need for motorcycle intake and exhaust manifold service and maintenance’ Wrenches and sockets: Wrenches and sockets of different sizes are needed to remove and install the intake and exhaust = = manifold bolts. A A & & A oi ca OD OePliers: Pliers can be used to remove and install hose clamps and other fittings. weyGasket scraper: A gasket scraper is used to remove old gaskets from the manifold and engine surfaces.Torque wrench: A torque wrench is used to tighten the manifold bolts to the manufacturer's specified torque settings.