Inlet Manifold - Installation

Warning - General - Stabilise Motorcycle

warning
Make sure the motorcycle is stabilised and adequately supported.A correctly supported motorcycle will help prevent it from falling.An unstable motorcycle may fall, causing injury to the operator or damage to the motorcycle.

Inlet Manifold Install LG1; LGX

  1. Install new seals to the inlet manifold casting and fit the casting to the cylinder head. Refit the fixings and tighten to 8 Nm in the sequence shown below. Tighten the fixings a second time in the same sequence to 8 Nm.
    2. Inlet manifold casting sequence LG1 (ckyq)

    Inlet manifold casting tightening sequence

  2. Make sure the mating faces of the inlet manifold casting and inlet manifold moulding are clean and free from debris.
  3. Install new seals to the inlet manifold moulding and refit the moulding to the inlet manifold casting. Tighten the fixings 8 Nm to in the sequence shown below.
    4. Inlet manifold moulding sequence LG1 (ckyr)

    Inlet manifold moulding tightening sequence

  4. Retighten fixings 1 and 2 to 8 Nm.
  5. Install the tie bar fixing and tighten to 8 Nm.
  6. Check the condition of the intake air temperature sensor rubber washer and replace if necessary.
  7. Make sure the threads of the intake air temperature sensor are clean and apply Threebond 1360.
  8. Install the intake air temperature sensor to the inlet manifold moulding and tighten to 1 Nm.
  9. Reconnect the intake air temperature sensor to the engine subharness.
    10. Inlet Manifold Lower LG1_1 (ckxy)

    1. Tie bar fixing

    2. Inlet manifold moulding

    3. Intake air temperature sensor

  10. Refit the fuel rail assembly to the inlet manifold casting and tighten the fixings to 4 Nm.
  11. If the restrictor in the MAP hose has been removed, refit the restrictor (see Manifold Absolute Pressure (MAP) Hose Restrictor).
  12. Reconnect the MAP sensor hose and purge valve hose to the inlet manifold moulding.
    13. Inlet Manifold LG1_1 (ckxx)

    1. MAP sensor hose

    2. Inlet manifold moulding

    3. Purge valve hose

  13. Reclip the harness to the inlet manifold moulding as noted during removal.

Perform the following operations

Perform the following operations:

Purge Valve - Install L Series

Throttle Body - Install L Series

Airbox - Install L Series

Fuel Tank - Install L Series

Battery - Install L Series

Seat - Install L Series