Air Plenum upgrade

[Lobocop]

A year ago I purchased a 2008 Teryx from Beartooth Kawasaki and have loved every moment sitting behind the steering wheel. It has been used to haul gravel, pull a drag for clearing property, play in the sand dunes, and rock climbing in the high mountains of Nevada. It has never failed me, but it does have a weekness that needs to be addressed if you have one and use it in extremely rough conditions ... the air plenum, supplying air into the carbs, from the air cleaner, needs a small modification.

With hard use, jumping the dunes, rock climbing or any activity that jars the Teryx (or your spine) the air plenum can seperate from the carbs allowing sand/dirt to bypass the air cleaner and go straight into the carbs. This seperation can also happen if you tighten up the plenum clamps to much (compressing the plastic creating a beveld clamping surface).

There is a cure to this potential problem and it doesn't tear your wallet apart ... Plenum Rings are available from your dealer if you intend to really use your Teryx and they are easy to install.

To install the plenum rings takes about 45 minutes and starts with removing the seats and console cover ...



After removing the seats and cover I suggest you blow the dust/sand away from the engine area before continuing. The next step is to loosen up the plenum clamp, blowby hose, and removing the 4 bolts holding the air cleaner canister in place, remove the canister leaving only the plenum attached to the carbs ...

(air cleaner canister removed)


With the canister removed, loosen up the two hose clamps holding the plenum in place and remove the plenum ...



Looking at the bottom of the plenum you can see where the problem is. Where the hoses attach the plastic material is extremely thin and will compress if the clamps are installed to tight essentially helping the plenum pop loose, add to that oil residue from the engine blowby and it is almost a given it will come loose ...

(base of plenum showing the thin material at the attachement points)


A cure and peace of mind to prevent seperation is to install the billit aluminum plenum rings. They are essentially machined rings that hand press into the plenum preventing the plastic from compressing and there is a slight lip that imbeds itself into the rubber attachment (intake) tubes ...

(the rings installed)


After installation of the rings reverse the disassembly process and have some peace of mind if you intend to get into some serious playtime with your Teryx.

[trikebubble]

Fake plenums! What is this world coming to?

Great post their Ken, and good pictures too. Now just keep the jumping to a minimum, ok.

[Lobocop]

Originally Posted by trikebubble

Fake plenums! What is this world coming to?

Great post their Ken, and good pictures too. Now just keep the jumping to a minimum, ok.

The engineers could have done a better job with the plenum, but doubt they really knew the capabilities of the Teryx ... it loves to play rough

I don't jump mine, but it has been known to go up and over some large rock formations and that can jar about everything ... including your soul

[2WheelFun]

Plenum Perscription. Even machines have ailments that need attention. Good job with the fix, Ken!

Where's the jump ramp?

[Lobocop]

This is about as close to a ramp that I will get.

This hill is extremely soft sand, and that sand is a lot like sugar in consistency.

YouTube - weeksmpeg

What goes up is supposed to come back down also ...

YouTube - DownWeeksHill

Enjoy

[2WheelFun]

Nice video's, Ken. You might have to build a ramp to really test the suspension.