Air Plenum Fix "How To" - Kawasaki Teryx Forum
How - To For Modifications, Bolt-Ons, Maintenance and Troubleshooting How-To's - Pictures make it better!

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post #1 of 34 (permalink) Old 04-04-2009, 08:42 AM Thread Starter
 
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Air Plenum Fix "How To"

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.
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Last edited by SandJunkie; 04-04-2009 at 08:53 AM.
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post #2 of 34 (permalink) Old 04-04-2009, 09:03 AM
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Nice!!!good post!
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post #3 of 34 (permalink) Old 04-04-2009, 10:02 AM
 
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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

Last edited by mnjettr; 04-04-2009 at 10:05 AM. Reason: Automerged Doublepost
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post #4 of 34 (permalink) Old 04-04-2009, 10:42 AM
 
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nice job and great step by step info, thanks for the tip
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post #5 of 34 (permalink) Old 04-04-2009, 11:24 AM
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Good tip..
Thank you.
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post #6 of 34 (permalink) Old 04-04-2009, 11:33 AM
 
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Great Information! Thanks for the step by step details!

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post #7 of 34 (permalink) Old 04-04-2009, 11:58 AM
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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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post #8 of 34 (permalink) Old 04-04-2009, 12:11 PM
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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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Last edited by GlamisBoy; 04-16-2011 at 10:34 AM.
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post #9 of 34 (permalink) Old 04-04-2009, 12:45 PM Thread Starter
 
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Quote:
Originally Posted by GlamisBoy View Post
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.
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...
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post #10 of 34 (permalink) Old 04-05-2009, 05:02 PM
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quick easy fix ... almost like putting a strap over a blower. see now thats a boater
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post #11 of 34 (permalink) Old 04-05-2009, 06:14 PM Thread Starter
 
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post #12 of 34 (permalink) Old 04-05-2009, 07:15 PM
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Quote:
Originally Posted by jeepinbeav View Post
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
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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post #13 of 34 (permalink) Old 04-05-2009, 07:29 PM
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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
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post #14 of 34 (permalink) Old 04-05-2009, 07:45 PM Thread Starter
 
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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...
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post #15 of 34 (permalink) Old 04-15-2009, 03:42 PM
 
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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
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post #16 of 34 (permalink) Old 04-15-2009, 04:44 PM
 
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good job, sounds affordable too. got any pics?
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post #17 of 34 (permalink) Old 04-15-2009, 06:44 PM
 
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Here is a sneak peak ...... PM me to get your on order.


Last edited by DASARACING; 04-15-2009 at 06:49 PM.
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post #18 of 34 (permalink) Old 05-05-2009, 02:39 PM
 
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These are now instock and can be purchased right off our website.

CLICK HERE
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post #19 of 34 (permalink) Old 05-15-2009, 09:04 PM
 
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Thumbs up

Thank you again DASA. The sleeves work great and are very tight.
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post #20 of 34 (permalink) Old 05-16-2009, 05:06 AM
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X2...Cleaned all mating surfaces with carb spray,sanded all surfaces with 220 and installed. Could not pull the boots off the plenum with almost a full all out pull with my hands!!! Great fix...now..just need you guys to make a bracket so we can have a straight shot from the plenum to air box("S"boot delete kit).

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post #21 of 34 (permalink) Old 05-16-2009, 06:26 AM Thread Starter
 
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Quote:
Originally Posted by SRX View Post
X2...Cleaned all mating surfaces with carb spray,sanded all surfaces with 220 and installed. Could not pull the boots off the plenum with almost a full all out pull with my hands!!! Great fix...now..just need you guys to make a bracket so we can have a straight shot from the plenum to air box("S"boot delete kit).
We actually tried that and unless you know how to make the CV carbs work? It works against you...but we're working on a carb mod now...shouldn't be too much longer...we need to get out of that exhaust so we can move onto other things..
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post #22 of 34 (permalink) Old 05-16-2009, 08:18 PM
 
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Thank you again DASA. The sleeves work great and are very tight.
RIGHT ON .... thanks for your business.

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post #23 of 34 (permalink) Old 12-28-2009, 05:06 AM
 
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? Tires

4x4pac,com ; What kind of tires do you have on your Teryx? I like the tread design you have! My swamp-foxes have a tread design something like yours!
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post #24 of 34 (permalink) Old 02-10-2010, 07:52 PM
 
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Ah, new here so really do not know the score, but as an outside observer I have a question. Why doesn't the manufacturer provide this fix in a recall type situation? You guys would not be adding zip ties or going to all this trouble unless it was necessary. If necessary then the factory should eat this cost, as it was their mistake, not Joe purchaser. Am I wrong here?

Oh, reason I am on here looking around is I hope to buy one soon and just learning what I can before the big purchase. Looked at RZR and it was too cramped in the cockpit for me. Rhino was OK. Teryx was so much nicer cab wise and easy to get in and out of. Past a certain age, getting in and out without a lot of body contortions is a big deal. I'm 6 foot 200 lbs. My hunting buddy is 6'4" and I'd bet he is pushing 400.

Thanks to all for the great advice.
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post #25 of 34 (permalink) Old 02-10-2010, 08:45 PM Thread Starter
 
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Quote:
Originally Posted by Goober View Post
Ah, new here so really do not know the score, but as an outside observer I have a question. Why doesn't the manufacturer provide this fix in a recall type situation? You guys would not be adding zip ties or going to all this trouble unless it was necessary. If necessary then the factory should eat this cost, as it was their mistake, not Joe purchaser. Am I wrong here?

Oh, reason I am on here looking around is I hope to buy one soon and just learning what I can before the big purchase. Looked at RZR and it was too cramped in the cockpit for me. Rhino was OK. Teryx was so much nicer cab wise and easy to get in and out of. Past a certain age, getting in and out without a lot of body contortions is a big deal. I'm 6 foot 200 lbs. My hunting buddy is 6'4" and I'd bet he is pushing 400.

Thanks to all for the great advice.
Don't worry...it was only a problem on the 08 carb model...they went to fuel injection on the 09 and newer so there is no more problem...everyone that has a 08 has pretty much solved the problem and moved on with their lives...
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