Gday all, its time to change rubber boots on inlet an I have some simple questions:

1. Is there enough space between cylinder head and frame to move plenum and throttle body and mount new rubber?

2. Any special tips, tricks about it like heating, lubing etc?

Thanks in advance

its almost impossible without taking off the plenum and tank nino

then the throttle bodies to get to the head fitting ones

don't forget to seal the head flange gaskets with a little diebond 1209 sealant ...and let it go off for a while before fitting,  do not over tighten the retaining screws

I have also noticed that there is a little ridge along the bottom of those rubbers (made to position to the head ?)  that I removed on mine to get a good seal .

don't forget to position the head fitting rubbers central to the inlet port ...not just the way that they seem to fit ....test with your finger how much clearance is around the fitting of the runners to the port ...as a few tenths of a millimetre out could make a great difference to the performance of the engine
not so good



better



I would advise to use some lubrication on the rubbers when trying to refit them up also

there is a ridge built into the castings of the throttle bodies upper and lowers that adds additional complication and restricts easy fitting





good luck   ! and hope it solves some issues for you

cheers

charlie99 wrote:its almost impossible without taking off the plenum and tank nino

then the throttle bodies to get to the head fitting ones

don't forget to seal the head flange gaskets with a little diebond 1209 sealant ...and let it go off for a while before fitting,  do not over tighten the retaining screws

I have also noticed that there is a little ridge along the bottom of those rubbers (made to position to the head ?)  that I removed on mine to get a good seal .

don't forget to position the head fitting rubbers central to the inlet port ...not just the way that they seem to fit ....test with your finger how much clearance is around the fitting of the runners to the port ...as a few tenths of a millimetre out could make a great difference to the performance of the engine
not so good



better



I would advise to use some lubrication on the rubbers when trying to refit them up also

there is a ridge built into the castings of the throttle bodies upper and lowers that adds additional complication and restricts easy fitting





good luck   ! and hope it solves some issues for you

cheers

Thanks Charlie. What kind of clamps to use?

I managed to change all of mine without removing much. The top rubbers come off the throttle bodies quite easily and then the bank of bodies comes off in one piece. I used a smear of silicone grease on mine where the rubbers touch metal - the RAF taught me that.
The throttle bodies were then balanced, I took my time with this bit, and the bike was transformed.
Mine is a 16v, not sure if the job is much different.

hi nino

have a look though the forum
there is the part numbers for the Suzuki clamps ...which are adjustable and re-useable

don't have the link at this moment ...sorry ..ill have a look though

I have had the adjustable ones on the lowers ...but haven't yet bought the ones for the uppers

(pst ...I just opened up the top clamps with circlip pliers to expand at the crush point ...then after refit closed them up again for a good seal ...if you use the real octeker pliers for the clamping they become a cut off job as the creases in the metal make It nearly impossible to expand the clamps with out metal fatigue and breakage - failure )
 seal them up with a good set of side cutters

bikerboy wrote:I managed to change all of mine without removing much. The top rubbers come off the throttle bodies quite easily and then the bank of bodies comes off in one piece. I used a smear of silicone grease on mine where the rubbers touch metal - the RAF taught me that.
The throttle bodies were then balanced, I took my time with this bit, and the bike was transformed.
Mine is a 16v, not sure if the job is much different.

The 16v have an O-ring and the 8v don't have one so you have to use sealant and it is awkward getting enough room to do the sealant properly.

some good information here

https://www.k100-forum.com/t1651-leaky-intakes-rough-running

Rick, you wrote that earlier K 8 V doesnt use O ring on head. Are you shure cause my part supplier told that I need O rings

Chris Harris uses alcohol as a lubricant to jam Throttle Bodies into rubbers in his videos. Alcohol as in rubbing alcohol not whiskey  It evaporates.

Yep quite sure

confirmed nino

no oring in there

there is what looks like a relief for an oring   but nada

charlie99 wrote:have a look though the forum
there is the part numbers for the Suzuki clamps ...which are adjustable and re-useable

48mm Suzuki band clamp   09402-48208 for TB->bushings and bushings->air plenum connections.  Cost about $4.75 each.

When you use the hose clamps (suzuki or others) it's a bit fiddly to position them so the worm drive bit doesn't foul the movement of the TB arm.  There is not much room for error there.

When doing this, be careful not to knock the TPS out of position so that it holds the throttle open - and then spend the next hour trying to figure out why the bike wants to idle at 6000 RPM. (DAMHIK)

Positioning the clamps is best done while opening and closing the throttle repeatedly. It's annoying if like me you struggle when things don't line up but I couldn't get them all the same and still be able to do up the clamps.

Although it's more annoying when you find out you can't open the throttle because a clamp is blocking it.

Thanks for quick answering. Anybody know what is inside diameter of manifold rubber? Is it same on both sides? Or what is outer diameter of thr. bodies in place where rubber sits?

Regards

40.10 mm od round about ...top and bottom of the throttle bodies nino
don't forget the ridge of about .5 mm about 4.5 - 5mm from the top

39.78 mm for the bottom rubbers id  tb end
31.5 mm id on the head rubbers measuring the rubber as it connects to the head

the top rubbers measure 42.00 mm and 39.2 mm id

these are old rubbers ...so may have changed from new ...slightly

robmack wrote:

charlie99 wrote:have a look though the forum
there is the part numbers for the Suzuki clamps ...which are adjustable and re-useable

48mm Suzuki band clamp   09402-48208 for TB->bushings and bushings->air plenum connections.  Cost about $4.75 each.

Hi all,
Does anyone know if these 48s will also tighten down to the 46.5 so I only need to order the one size throughout?
Cheers, Stu

Light smear of pure silicone grease on all rubber surfaces helps with the fitting and keeps the rubbers soft for longer, only use ty-wraps (cable ties) for securing never had any leaks.