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Please read all of these instructions. There are a lot of helpful tips that will make installing your new intake easer. If you are not a qualified mechanic, please take your bike to one. Improper installing of this intake can cause serious injury or even death. Know what you are doing before attempting this. If you are not the owner, forward these instruction to the owner/operator of the bike. All Innovative Design & Concepts merchandise is warranted to be free from defects in material and workmanship. It is the responsibility of the purchaser to inspect all merchandise carefully before use. Credit, repair or replacement of goods in predicated upon factory inspection of merchandise in question. REMOVAL OF ORIGINAL INTAKE: Use a shop manual to do the following: You will need to drain your coolant system, remove the coolant catch bottle assembly, remove the original intake system and remove thermostat housing. SWITCHING PARTS OVER TO NEW INTAKE: Before you remove your parts from your intake, take a ohm reading of your TPS. Make note of the reading when the throttle plates are closed. Fig 1 Remove the following parts from your original intake system: Fuel injectors including the o-ring in between the 2 fuel rail halves, MAP sensor, 2 sync screws w/springs, throttle cable mount plate, throttle cable wheel w/ set screw and lock nut, 2 rubber mounts w/ spacers from the bottom side of the intake, vacuum cap and the TPS. When removing the TPS, you will have to grind the rivet heads off to remove the TPS. Be careful not to melt the plastic when grinding the rivets. You can also use a small sharp chisel on the metal washer and rotate the washer to loosen it but be careful not to break the plastic. Reinstall your parts on your new intake in the following order: MAP sensor (including o-ring) turn the MAP sensor so the wire connector can plug in from the right side, throttle cable mount, set screw w/nut, throttle cable wheel (remove top spacer from shaft, install spring, throttle cable wheel, reinstall top spacer and install linkage rod top assembly.
Tags : honda vtx 1800, coolant system, 2005 honda vtx 1800, metal washer, free from defects, rubber mounts, throttle cable, easer, assembly instruction, wire connector, lock nut, fuel rail, o ring, fuel injectors, bottom side
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