Throttle Body Re-Hab and other Rubber repairs...

[552255]

After smelling gas after a ride, I checked my fuel lines, one had sprung a leak.  After deciding to replace them all (quite a bit of work) I looked at the rubber throttle body bushings, and the oil-airbox-vacuum-thingy hose that always goes bad,  they all are needing replaced.

The bushings were sneaky in that it was difficult to see/notice a split, after gently pushing on it with a screwdriver--sure enough!  The O-rings below the plastic intakes are shot as well, with one seemingly showing leakage into the engine I suppose.   Sheesh, and the bike was running pretty good I thought.  (Minor leakage now, sure to get worse...)

Two 'tips' I suppose:  I didn't unhook any of the throttle/choke cables, the 'bodies' just rotated over/up as in photo, and the fuel injectors/rail/manifolds--ditto.  I think/hope this may work to install back together without removing injectors, etc.  (I don't want to have to disturb the O-rings on them, but should I replace them as well?...they seem ok and easy enough to take out if needed in future)

The next is an observation...the air filter is original, with 30k miles and looks barely dirty! (I will vacuum/blast it clean)   

NOTE: "...when in Rome, replace the rubber..."  30 bucks of fuel line/clamps has turned into another 90 bucks in parts and downtime...should say thanks to the great posts here about performing these fixes.  Once the the plastic is off, the job isn't too bad.

Since that filter wasn't too bad, I thought I'd try "washing/rinsing" it,  seems to have cleaned up very well with dishsoap and a bit of brushing, vacuum dried out etc.  The paper is more durable than I thought...
 

[branandfox]

I installed remanu'd injectors on my lady. they are a nice little addition to the system! if you are into all that jazz... a few other guys tried them out as well. duck might have I believe and can attest to them being a good upgrade. might be worth it just to throw them in and have a spare set of injectors around! I replaces my filter with much more of a princess UNI filter but the K&N's will last foreverrrrrrrrrr. give it a good blast with an air can and vacuuming and you should be good to go by friend! rubbers are espensive but it keeps the ladys happy if you know what I mean :2thumbup: If your interested in the injectors then Just PM me and I will tell you where to get them, no need to spam your thread! hope you get her road worthy soon!

[552255]

Follow up for anyone reading or thinking about doing this, or fuel lines:

The short fuel line from regulator to rail, with the 90deg. bend...I could not get straight hose to work, it was too much bend--more acute than 90d--to work. (I check'd Drake's and Mystic Reds' post re: fuel lines.....yoga knowledge :dunno2: or different hose maybe?) The line just collapsed on itself...need the pre-formed hose/fitting/or something else to make that corner.  Hose was Gates--225psi.  Had to order the $17 pre-formed hose from dealer. 

Another note:  replacing the one-time 40mm? clamps...a bit tough to find due to the width.  I ended up using big zip ties on the intake tubes, and stainless zip-ties on the upper bushings.  If you use a screwdriver to push/leverage with against the 'lock' part of tie, you can get them tight with some type of pliers.   Then run bike and spray areas with starter fluid to check for leaks...

[Motorhobo]

Re fuel lines -- the previous owner of one of my k75s put on a non OEM on the one that runs to the front of the fuel rail -- thicker wall hose than the OEM but seems to make the bend fine. I used NAPA hose from the rear of the fuel rail to the pressure regulator. The other one I think is too bendy to go with anything but OEM...