Air Intake Plenum Break

Gorilla · Oct 16, 2015

Well here is a good one. MJ was riding her Stallion last night. We went to dinner came out and rode about 4 miles and stopped at a Publix for some milk. Came out started the Stallion and when we started to give it some gas it died just like it ran out of gas. we know it had at least 3 to 4 gallons so that was not the problem.

It would start and idle even in gear but push on the pedal and it would die. We idled down the street for 3 miles in traffic to the motel. I figured fuel filter or maybe fuel pump. Got up made arrangements at a garage to look at it and called AAA to have it towed.

While I was waiting I opened the hood to make sure I remembered where the data port was and noticed that the air intake plenum looked strange. Looked at it closer and it was completely broke in half where the air filter and plastic sectioned that the MAP sensor are mounted and attaches to the section of the plenum that goes to the throttle body.

It appears that the plastic failed from getting brittle over the 7 years of heat and vibration. I had some repair tape wrapped it nicely to put the whole thing back together sealed. That fixed the problem.

With the MAP sensor not being able to read moving air (the sensor was down line from the break) the ECM would not let the Fuel Injection work. No air No gas. Something to be aware of as our Stallions are aging. I will be looking into seeing if I can replace the plenum. Works great for now.

Ed Hobgood · Oct 18, 2015

Duct tape works wonders! Wouldn't leave home without it.:clapping: K&M might have a replacement for our Stallions.

Gorilla · Oct 19, 2015

Ed Hobgood said:
Duct tape works wonders! Wouldn't leave home without it.:clapping: K&M might have a replacement for our Stallions.

I looked and did not see anything. I think I can repair it if need be.

Roadbuz · Oct 20, 2015

Air intake an plenum break

Gorilla, MJ and all Stallion Owners take note:

We Own Two 2008 Stallions and have had both of our trikes brake down from the same issue within literal DAYS of each other.

We called Texas and were told we must first contact a local shop and have them call in the order for the part, which we were led to believe was a special "ROUSH" part and was on a three month back order at $ 100 each!

I tried a hi heat glue to seal the splits and wrapped them over with self adhering black hi heat tape and they worked for just a short bit and began to fail in other places. I want to be sure we are both talking about the same part, I will include fotos of our parts and will skip other means we tried to repair the problem.

Ours failed at the rubber "L" cold air intake tube which runs from the throttle body and takes an immediate 90 degree bend with very little room before it contacted the angular brace nearly in front of said tube. It plugs into another rubber tube which houses the map sensor, filter,etc.

After much experimenting, I finally came up with a working fix, which has continued to work on both bikes with some adequate mileage and in our August-Florida-heat as tests. As it is early in the morning here, I will get all parts when the store opens and their respective numbers and those fotos taken ASAP.....BTW all were purchased at my Auto-zone stores.

LT

Ed Hobgood · Oct 20, 2015

Thanks for any information you can give. This is what I love about TT, you can get information from other Stallion owners and what they have done to correct their problem.

Roadbuz · Oct 20, 2015

My fix for my worn Plenum pipes.........

Fotos show one thousand words..I have managed to load two, but I have been under the weather all day....this is the first time I have been able to sit still for more than a few moments....I will do my best to try and recall how to get fotos uploaded and a brief commentary as to how I managed to combine some parts from of all places, my local Autozone. I had contacted several "speed shops" and several like shops and none of them cold manage to come up with a fix.

The part numbers needed are (1) #422454 8741 Spectre Air Duct Hose and
the only part I used from the previous was the hose (the diameter will easily slide onto the pipe housing the MAP sensor....luckily for me, the hose was long enough to use to fix both trikes I purchased (2) #422454 8776 Spectre Blue Intake Couplers (believe they were 3" dia)....obviously most will only need one.

I (Believe) I have uploaded a foto of worn plenum intake pipes and my fix..fingers crossed...

a dab of lube on either throttle body or inside new pipe helps...

I found it easier to secure pipe inside Blue coupler and bunching up rings of piping to form roughly enough that ring clamp has something to bind against.

Leave ring clamp which secures it to throttle body fairly loose..
work onto throttle body..it can be done...it's a real pain...butt..lol

The Spectre Air duct assy. price was $19.99
(was great, for me, as the tube was more than twice the length needed for one)
The Spectre Blue Intake Coupler was $7.99

For what it's worth.....I humbly offer an alternative

OH...BTW...My wife bought a certain Yellow Stallion most will recognize from two great folks on here...(Hint: it had pinstriping by Mountainman)

THX.."LT"

deanhauser · Oct 21, 2015

Thanks Ron, that was very helpful. I just replaced my air filter and didn't see anything unusual, but will go and check the hose a little closer now.

Roadbuz · Oct 21, 2015

Thanks one and all

deanhauser said:
Thanks Ron, that was very helpful. I just replaced my air filter and didn't see anything unusual, but will go and check the hose a little closer now.

Dean?, Your symptoms will be as Gorilla described when the damage is done, I'm happy to offer any assistance as I have received more than I have given, thanks to the good people here. Gorilla and I managed to catch it, but the damage was done. Perhaps this may make people aware of a potential problem area and gives a meager alternative at minimal cost and the trike can be on it's way relatively quick, compared to a minimum of two to three months of backlog. P.S. I worked in "The Springs" for a few years, back around Y2K, loved it!"How about you?

Gorilla · Oct 21, 2015

Roadbuz nice solution. Thank you. The tape I used is holding for now but as you stated the heat will get to it as it's not a permanent solution. Yours looks like you have the answer. I hope she enjoys Nat's trike. Knowing Mikey it was as well taken care of as possible. I actually looked to but it but you had all ready scarfed it up. Enjoy. I will get your recommended parts and fix MJ's.

Roadbuz · Oct 23, 2015

Cold air intake problems...

Guyz and Dollz,

Regarding the pipe which has the MAP sensor in it, I found several places where that could be duplicated. My problem was with the "L" pipe which attaches to the throttle body. Clearance is the issue, in that the diagonal brace just in front of that pipe was so tight. I had tried many shoppes and parts companies and simply experimented with several types of fixies until the one I finally came up with.

We have ridden both trikes throughout Biketoberfest and logged some decent miles pushing them fairly hard. So far, without any problems. If anyone needs the part numbers from Autozone check back in my earlier message. Will keep all abreast. Btw, does everyone know you can clean your k&n filters, re-oil them and reused them? Kits are also available from Autozone for that purpose .

Now, I can safely cut the tabs off zip ties I used to keep the flex pipe off the large pully below. Side note: If you ever try to start your Stallion and it simply dies immediately or runs roughly...check these tubes first...Regards "LT"

trikervet · Aug 19, 2016

My intake hose gave up the ghost a few days ago. I called TBMS and they had them in stock, but I would have to get a shop to order it from them.

Richard told me they do not accept orders directly anymore. A shop must place the order. Anyway, I went through a local shop and they had it here in 2 days.

The part itself is $99. and change. After tax and shipping it was $123.03 The part number for the hose is ST06-ENOO-A050-0020. I did a Google search

just for curiosity and came up empty.

Back when Gorilla had his problem, I checked mine at that time, squeezed, etc. and it was okay. I happened to be at my house when it broke, so I didn't

get stuck on the road.

Doc7402 · Mar 11, 2017

Roadbuz said:
Fotos show one thousand words..I have managed to load two, but I have been under the weather all day....this is the first time I have been able to sit still for more than a few moments....I will do my best to try and recall how to get fotos uploaded and a brief commentary as to how I managed to combine some parts from of all places, my local Autozone. I had contacted several "speed shops" and several like shops and none of them cold manage to come up with a fix.

The part numbers needed are (1) #422454 8741 Spectre Air Duct Hose and

the only part I used from the previous was the hose (the diameter will easily slide onto the pipe housing the MAP sensor....luckily for me, the hose was long enough to use to fix both trikes I purchased (2) #422454 8776 Spectre Blue Intake Couplers (believe they were 3" dia)....obviously most will only need one.

I (Believe) I have uploaded a foto of worn plenum intake pipes and my fix..fingers crossed...

a dab of lube on either throttle body or inside new pipe helps...

I found it easier to secure pipe inside Blue coupler and bunching up rings of piping to form roughly enough that ring clamp has something to bind against.

Leave ring clamp which secures it to throttle body fairly loose..

work onto throttle body..it can be done...it's a real pain...butt..lol

The Spectre Air duct assy. price was $19.99

(was great, for me, as the tube was more than twice the length needed for one)

The Spectre Blue Intake Coupler was $7.99

For what it's worth.....I humbly offer an alternative

OH...BTW...My wife bought a certain Yellow Stallion most will recognize from two great folks on here...(Hint: it had pinstriping by Mountainman)

THX.."LT"

Just checking in Ron on your hose fix , as mine just broke during a parade today will need a fix also Doc 813-469-9921

Gorilla · Mar 11, 2017

Doc I did MJ's with this suggestion awhile ago and it has worked great. I fashioned a couple of tie-wraps to provide support is all.

Gorilla

Doc7402 · Mar 12, 2017

Gorilla said:
Doc I did MJ's with this suggestion awhile ago and it has worked great. I fashioned a couple of tie-wraps to provide support is all.

Gorilla

Have a number i can call you on ?

tomg · Mar 13, 2017

Roadbuz said:
Guyz and Dollz,

Regarding the pipe which has the MAP sensor in it, I found several places where that could be duplicated. My problem was with the "L" pipe which attaches to the throttle body. Clearance is the issue, in that the diagonal brace just in front of that pipe was so tight. I had tried many shoppes and parts companies and simply experimented with several types of fixies until the one I finally came up with.

We have ridden both trikes throughout Biketoberfest and logged some decent miles pushing them fairly hard. So far, without any problems. If anyone needs the part numbers from Autozone check back in my earlier message. Will keep all abreast. Btw, does everyone know you can clean your k&n filters, re-oil them and reused them? Kits are also available from Autozone for that purpose .

Now, I can safely cut the tabs off zip ties I used to keep the flex pipe off the large pully below. Side note: If you ever try to start your Stallion and it simply dies immediately or runs roughly...check these tubes first...Regards "LT"

Ron, I use simple green, spray it on the filter, let it set for 10 minutes or so, hose it off with water and I blow out the water from the inside to the outside with my leaf blower. Let it set in the sun until dry and give it a light coat of filter oil which you can get a any parts store. I do this every 10k miles. That K&Natalie filter is good for a million miles.

Tom

Gorilla · Mar 13, 2017

Doc7402 said:
Just checking in Ron on your hose fix , as mine just broke during a parade today will need a fix also Doc 813-469-9921

Doc here is a picture of the finished repair

Doc7402 · Mar 19, 2017

Replacement INTAKE PLEMIN ( Air Filter ) intake

First i'd like to thank every one for their input. As OUR TRIKES ARE GETTING OLDER THIS MAY OR WILL HAPPEN TO YOU. After doing some research i have found that SPECTRE PERFORMANCE AIR makes a replacement for it.. It can be bought in four difference colors , Black #8741 , Blue 8746 , Red 8742 and also chrome which i could not find a number for . Since My Trike is red i went with the red color . The hose is all you will need , remove the three hose clamps 2 of which are the large 3 1/2 inch for the center tube and the third is a small 1 inch located close to the air filter , these three hose clamps will be all you will need to do the replacement . I also unplugged the Mass air flow sensor . just to make it easier to work on . As my old factory boot was stuck on i used a razor knife to cut the plastic , at both ends of the factory tube where they could be removed ( BE CARE FULL NOT TO CUT / PRESS HARD ) and cut throttle body intake as it's also plastic , i nicked mine finding out the hard way . While i had it off i cleaned the air filter also , in all about 30-45 minutes longest cleaning the air filter. The flex hole comes with a boot also which i did not use. use the non-flex part at the throttle body while using the flex end at the other end where the mass air sensor and air filter attaches .YOU WILL ONLY BE REPLACING THE CENTER SECTION.... I found it on AMAZON .COM with shipping less than $20 for the RED and the Black is cheaper.....Have Fun Doc.. P.S. a little WD/40 sprayed on both ends of the tube will help sliding it on...

Gorilla · Mar 19, 2017

Doc I moved your post to the previous thread that dealt with this subject glad it worked out for you

Doc7402 · Mar 20, 2017

Doc7402 said:
First i'd like to thank every one for their input. As OUR TRIKES ARE GETTING OLDER THIS MAY OR WILL HAPPEN TO YOU. After doing some research i have found that SPECTRE PERFORMANCE AIR makes a replacement for it.. It can be bought in four difference colors , Black #8741 , Blue 8746 , Red 8742 and also chrome which i could not find a number for . Since My Trike is red i went with the red color . The hose is all you will need , remove the three hose clamps 2 of which are the large 3 1/2 inch for the center tube and the third is a small 1 inch located close to the air filter , these three hose clamps will be all you will need to do the replacement . I also unplugged the Mass air flow sensor . just to make it easier to work on . As my old factory boot was stuck on i used a razor knife to cut the plastic , at both ends of the factory tube where they could be removed ( BE CARE FULL NOT TO CUT / PRESS HARD ) and cut throttle body intake as it's also plastic , i nicked mine finding out the hard way . While i had it off i cleaned the air filter also , in all about 30-45 minutes longest cleaning the air filter. The flex hole comes with a boot also which i did not use. use the non-flex part at the throttle body while using the flex end at the other end where the mass air sensor and air filter attaches .YOU WILL ONLY BE REPLACING THE CENTER SECTION.... I found it on AMAZON .COM with shipping less than $20 for the RED and the Black is cheaper.....Have Fun Doc.. P.S. a little WD/40 sprayed on both ends of the tube will help sliding it on...

* * * * now have part number's for all four colors P/N Black 8741 , Red 8742 , Blue 8746 and Chrome 8748 ( wished i had found the chrome number before that's life , i may just order it for a spare... LOL

Doc7402 · Mar 21, 2017

Doc7402 said:
* * * * now have part number's for all four colors P/N Black 8741 , Red 8742 , Blue 8746 and Chrome 8748 ( wished i had found the chrome number before that's life , i may just order it for a spare... LOL

Ordered the chrome today..