Automotive Manual PDF

Preparation for Installation
1. Make sure that there are no metal chips or other debris inside the manifold. Check that all bolts will run freely into any tapped holes.
2. Note that while this manifold makes provision for all vacuum lines and other brackets or parts that attached to the stock manifold, the vacuum ports originally on the front side of the manifold have been moved to the back for a cleaner appearance. This will require the use of longer vacuum hoses in some cases.
3. Disconnect battery and drain coolant.
4. Mark and identify all hoses and valves.
5. Check the condition of all hoses, gaskets and o-rings. Replace as needed. Use a new intake gasket. Honda #17105-P72-004.
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1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Disconnect electrical connectors to throttle body & factory intake tube. See Fig#1
3. Using a 10mm socket, remove two bolts holding throttle cable bracket to intake manifold. Retain bolts for later use. See Fig#2
4. Remove throttle cable(s) from throttle body.
5. Using a Phillips screwdriver, loosen hose clamp on factory intake tube & remove tube from throttle body & air box. See Fig#3
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TO START:
1. Turn the ignition OFF and disconnect the vehicle’s negative battery cable.
2. Disconnect the air temperature sensor electrical connection as shown.
3. Unclip the battery cable from the air inlet duct as shown.
4. Loosen and remove the two bolts that secure the air inlet duct as shown.
5. Remove the air inlet duct.
6. Loosen and remove the four bolts that secure the air intake resonator.
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PREPARATION
1. Remove the EVAP hose, brake booster hose, PCV hose, vacuum hose, water bypass hoses, throttle cable, fuel lines, fuel injector connectors, IAC valve connector, TP sensor connector, MAP sensor connector, and EVAP canister purge valve connector from your current intake manifold and throttle body setup.
2. Remove the throttle body.
3. Remove the intake manifold brackets, intake manifold, and intake manifold gasket.
If adapting an Accord Euro R or 06 Civic Si intake manifold onto an 02-06 RSX/ITR or 02-05 Civic Si/CTR style head, continue to follow the remaining “PREPARATION” steps, otherwise skip to “INSTALLATION”
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1. Disconnect the negative battery cable! Remove the plastic wing nut on the air intake hat behind the throttlebody. Loosen the hose clamp that secures the flexible intake tube to the throttle body hat. Disconnect the crankcase breather hose. Roll the air intake hat towards the front of the vehicle to remove it, and set it aside.
2. A.) Remove the three bolts that secure the throttlebody to the intake manifold. B.) Remove the bolt that secures the throttle cable bracket to the throttlebody. C.) Lift up the tabs, and disconnect the two wiring harnesses of the drivers side of the throttlebody. Lift the throttlebody off of the intake manifold and set it to the side.
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Step 1
Set parking brake on vehicle and disconnect the negative battery terminal.
Step 2
Remove flexible inlet hose from throttle body and air box by loosening two hose clamps. Disconnect the tube to the valve cover and the inlet air temperature sensor if applicable.
Step 3
Remove plastic cover on the left side of the throttle body. Unhook the throttle cable from the throttle body link-age, disconnect the throttle position sensor and vacuum hose from throttle body.
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Removing stock carburetor and cables.
1. Remove seat, front fenders and gas tank. Make sure fuel petcock is in “ON” or “RES” position. If it is in the “PRI” position it will allow fuel through it.
2. Remove throttle cable, (and housing if installing a twist kit) from throttle housing. Pay close attention to routing when removing cable as the new cables will need too be routed the same.
3. Disconnect choke cable from stock carburetor before disconnecting it from handle bar and remove.
4. Remove stock carburetor.
5. Stuff a dry, clean rag into the intake manifold to keep debris from entering engine.
6. Remove stock rear head stay from frame and head.
7. Remove plastic vent box from right side of frame along with hoses.
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This manual contains information on how to do that; please read it carefully before operating the engine. If a problem should arise, or if you have any questions about your engine, consult an authorized Honda servicing dealer. INTRODUCTION Safety Messages Damage Prevention Messages Safety Information COMPONENT & CONTROL LOCATION Throttle Cable Connection LPG Connection Battery Connection BEFORE OPERATION CHECKS Is Your Engine Ready To Go OPERATION Safe Operating Precautions Starting the Engine Setting Engine Speed Stopping the Engine SERVICING YOUR ENGINE The Importance of Maintenance Maintenance Safety Safety Precautions Maintenance Schedule Refueling Fuel Recommendations Engine Oil Air Cleaner Spark Plug Spark Arrester
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Service Bulletin Subject: R1100/850 Model Throttle Cables Problem: Engine surges at constant speed. Difficult to adjust and balance the left and right throttle bodies. Cause: Differences in opening and closing of the throttle butterflies caused by friction in the throttle cable. Remedy: 1. Fit a low friction throttle cable. 2. Check the following to ensure optimum results: Ignition timing Spark plugs (FR 6DDC) type / condition (reference SI 2739 in Main Group 12) Valve clearances Correct Cat. code plug Check throttle housing inlet manifold for air leaks
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