I'm not sure how many are convinced that the air plenum connection to the carbs is a poor design on Kawasaki's part but for those of us who have had problems? Here is a cheap and easy solution that will keep you from rebuilding your engine prematurely. Originally I was going to try and make a buck off this but it came together so easy that I just thought I would throw it out there for most "do it yourself" guys & girls.

Materials needed:
1 - 7" Stainless band clamp
4 - M5 x 12 Stainless Allen Head Bolts
2 - M5 Stainless Flat Washers
2 - M5 Stainless Lock Washers

Tools needed:
Impact Driver (Do not attempt with out this)
Whitney Punch (Might be able to get by without this one...maybe)
Bulldog Tin Snips (Or a damn good pair of snips that you don't mind ruining)

Time needed:
About 2 hours

OK grab your 7" band clamp and measure down 7" from the clamping end and cut it with your snips...(Don't mind the holes...I got ahead of myself while taking pictures)...


Now cut 3" off the remaining end of the clamp...


Now use your Whitney punch and punch 2 holes 1/4" in from the end of the clamp on both pieces...(I smoothed out and radiused the ends on my grinder)...


Now remove the carb assembly (Just easier to work on this while it's on a bench or table) and start by using your impact driver to remove the 2 screws above the linkage assembly...


Take one of the M5 allen bolts and a FLAT washer...these will replace the screws you just removed. Make sure to use RED Loc-Tite (Threadlocker) on these. Use the bolt & washer to install the clamping end (7") on the rearward mounting hole...do not tighten this down until the last step




Turn the assembly over and use your impact driver to remove the screws holding the fuel "T" onto the carb assembly. Replace these with the 2 remaining allen head bolts and the LOCK washers. Use RED Loc-Tite on these also. Mount the remaining band piece on the FORWARD mounting hole this time like so...



Re-install the plenum to the upper boots on your carbs. Loop the band up and over the plenum and attach to itself. The whole thing should look like this...



NOW TIGHTEN the allen head bolts. Double check everything to make sure it's all tight and re-install your assembly.

We have another idea in R&D right now but rather than waiting around to hear more horror stories I rushed this out. Hopefully we saved some engines...

If any of you don't not have access to the tools or a local hardware store then PM me and I'll work something out with you to get the mod done.

Nice!!!good post!

very nice, I was thinking of something on that order but did the zip tie to get out riding the day I did mine.. next service I'm gonna do it that way, I know this will save some engines...good job

PS. I think this deserves to be a sticky

nice job and great step by step info, thanks for the tip

Good tip..
Thank you.

Great Information! Thanks for the step by step details!

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!!!52-Welsh Racing-52!!!

i never thought about making a permanent mount like that but now that i have seen it i will more than likely do this also. GREAT TIP a yes this should be a sticky

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The mad teryx scientist

Why not just drill a hole & run a bolt through. Placing a lock nut & washer on the other end. We did this 20 years ago on the Banshees carbs to hold the air filters in place. Cheap & easy to fix saving your motor from sucking sand.

Disclaimer: I've never looked at my plenum (if my '09 has one), nor have I seen the carb set-up. But looking at the pics seems like it would be another fix (plus I don't have a whitney punch......).

Just a thought.
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Mexico Hotels

You could but I'm sure there is someone out there who would have said that would interfere with the air flow or velocity or air box harmonics...or air would suck in around the bolt hole...

Whateveh floats your boat...and no your 09 does not need a fix...only the 08's...

quick easy fix ... almost like putting a strap over a blower. see now thats a boater

How true it is that YOU NEVER THOUGHT. Let someone else do the thinking for you then just copy. You wont hurt yourself that way!

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2009 Rex LE
27in. ITP's
3 in. PAC LIFT
PAC FRONT AND REAR BUMPERS
We build REAL bumpers, not a piece of bent tube!

good idea dude, I am sure their is a million ways to do this but yours looks really good...props to you for taking the time to take pics and share

Yepp...I am sure there is...I was just looking for something more permanent than the zip tie that was there...and about as inexpensive...

We have some billet stuff we were working on but I just kept coming back to this set up as the most positive connection that we could come up with...

If you have a 2008 teryx you need this item. No need to worry about your plenum coming off every again. Save yourself lots of $$$$$ with our low cost one time fix for this issue....... This fix will offer a solid clamping surface for both of intake boots. It will not disrupt the intake flow and they are simple to install. You will not see them once they are installed and the intake plenum will not come off EVEN IF YOU TUG ON IT once these parts are installed. They will be $49.99 ...... all pre-orders will ship 4/24/2009