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Replace K75 or K100 Intake Manifolds

Intake manifold - part 11611460408

Though it may or may not be necessary, you may want to also consider replacing the boots above the throttle bodies (4) as well - part 11611460755.  From the factory these are attached with one-use 48.5 mm (lower) and 50 mm (upper) Oetiker clamps. I usually replace these with 5/16" stainless steel hose clamps to simplify future maintenance and eliminate the need for an Oetiker clamping tool.

1) Disconnect the front fuel line from the fuel tank and both fuel lines from the fuel rail.

2) Loosen the large hose clamp at the back (right front on the bike) of the air box above the throttle bodies. (a.k.a. plenum)

3) Remove the lower Oetiker clamps. (I cut them off with a Dremel cutting wheel.)

4) Disconnect the crank case breather hose at the rear of the plenum.

5) Pull the plenum towards you to remove it.

6) Pick the wire clip off of the throttle position sensor connector and disconnect it.  (Light blue circle above.) Put the wire clip back on the connector so it doesn't get lost. When you reinstall this you don't need to take the wire clip off as it will slip over the tangs on the sides of the TPS's connector to lock in place.

7) Disconnect choke cable.  First undo its locknut and then unscrew it all of the way in order to get enough slack in it to disconnect it.

8) 1990 and earlier: follow the wires for the choke switch to its connector and disconnect it.

9) Remove the screw type hose clamps the hold the throttle bodies in the intake manifolds. Note their positions as you'll want to reinstall them in roughly the same place in order to keep them from interfering with throttle movement.

10) Remove the throttle body assembly.

11) Each intake manifold is held on by two machine screws. Remove those and then remove the intake manifolds.

12) Clean their mounting surfaces and install the new intake manifolds. (9 Nm - 80 in-lbs)

13) Installation of the remaining parts is the reverse of removal.

14) Synch the throttle bodies.