Can-Am Maverick R Billet Intake Manifold

Remove wind dam. (2) push darts and (2) T-30 screws. Pop the front grill out of (4) grommets.

Remove the driver side foam insert. (4) 10mm screws, (1) T-30, push out the intake duct.

Remove the passenger side foam insert. (3) 10mm screws, (1) T-30.

Remove the charge tubes from the intercooler.

Remove (1) 10mm screw holding the coolant reservoir to the intercooler tray. Pull the reservoir back from the firewall, out of the clip. Strap the reservoir up.

Disconnect both intercooler fans from the OEM harness.

Remove (6) 10mm screws on the intercooler tray. Behind the seats, remove (4) rubber plugs and access (4) 10mm screw. Total of 10 screws.

Remove the intercooler.

Remove the upper plastic cover on the plenum. (1) 8mm screw.

Remove the coolant hose, transmission hose, and EVAP hose if your model is equipped. Remove the lower plastic tray by removing (5) 8mm screws.

Spray all injector ports and plenum with brake cleaner and compressed air. You do NOT want anything falling into the injector ports. Remove (2) 8mm screws.

Carefully push down and remove the blue safety clip on the fuel quick connector. DON’T BREAK IT. Press down on the top black connector and remove the fuel hose from the fuel rail.

Remove the fuel rail with injectors attached. Flip the fuel rail 180 degrees. Unclip all injector electrical connectors.

Blow compressed air around the intake manifold where it connects to the head. Remove (8) intake manifold screws with an 8mm socket. The top right screw also has a ground wire connected.

Carefully remove the plenum from the head. Slide the two lower rubber grommets off the studs. Be cautious of the dip stick tube.

Once the intake plenum is removed, clean all surfaces clean of debris. Look into the head to make sure nothing fell.

Carefully remove the OEM intake gasket and sleeves. DO NOT TEAR. If gasket is bad, replace it with a new gasket 420450512.

With a clean gasket, apply dielectric grease to the gasket and sleeves and install into the billet plenum.

Remove the throttle body from the OEM intake manifold. It is easier to remove the worm drive on the charge tube adapter first.

Install the supplied throttle body O-ring into the billet intake manifold. Use dielectric grease.

Install the throttle body as shown in the photo below. Use supplied titanium hardware. Torque to 80 in-lb. Reinstall the charge tube adaptor and tighten worm drive.

Remove the MAPTS sensor from the OEM intake manifold. Use a T-30 socket. Inspect the sensor, apply dielectric grease and install into the new intake manifold. Use supplied M6x12mm titanium hardware.

Remove the (2) rubber grommets from the OEM intake manifold. Install them into the bracket supplied. Fasten bracket to the intake manifold with supplied hex hardware.

Install the intake manifold onto the vehicle. Align the runner ports and lower bracket grommets onto the studs.

Torque sequence below for intake manifold.

• Torque9 ± 1 N•m (80 ± 9 lbf•in)Intake manifold screws

The dip stick tube and plenum will be very close together. You can still check oil levels.

Reinstall the fuel rail, injectors, and connectors. We recommend upgrading to the billet fuel rail.

Install the new charge tube from the intercooler to throttle body, use supplied clamps.

Reinstall all other parts in reverse order.