K Series Big Bore Throttle Body

Install Tips:
Below you will find tips on how to install your new Hybrid Racing K Series Big Bore Throttle Body into a Honda K series equipped vehicle. *This product may not be legal for highway use. Hybrid Racing is not responsible for any direct or indirect, actual or incidental expense attributed to the use of any performance parts sold by Hybrid Racing LLC. Purchasers agree to all of the terms of this agreement upon the purchase of parts. More information can be found at www.hybrid-racing.com.

Package Contents: (1) Big Bore Throttle Body (1) Thermal Gasket (1) 1/8 NPT Nipple (2) Vacuum Plugs (4) 1/8 NPT Plugs (4) 25mm M8x1.25 Bolts (1) 10mm M6x1.0 Bolt (2) 15mm M5x0.8 Bolts (2) 20mm M5x0.8 Bolts (1) 16mm M5x0.8 Bolts (2) 8mm M5x0.8 Bolts

Features: Knife-edged 76mm inlet Anodized 6061-T6 Aluminum Bolts to RBC, RBB, and PRB Plenums Dual Concentric torsion springs Dual ball bearings Dual needle bearings Integral o-ring seals Allows multiple IACV configurations Allows use of cruise control Staked Butterfly Bolts

Install Guide:
This install guide does not show all steps for installing this throttle body into a vehicle as it is compatible with many applications. However, this guide addresses many of the key steps you will encounter when installing your new throttle body. Shown to the left is an illustration of most hardware included with the throttle body. For your convenience, most of the bolts for the throttle body have been supplied already threaded into their proper positions. Refer to this guide if you remove the bolts and need to determine where they were intended to go.

DO NOT REMOVE the graphite colored paint on the

rim of the butterfly. This paint is used to seal the throttle body from a vacuum leak. If there is a small amount of flaking, still do not remove it. If it comes off and goes into the engine it will not hurt the engine since the paint is carbon based.

Step 1:
Before installing your throttle body, you will need to remove the two M8 studs that are installed from the factory on your intake manifold. This is because the throttle body will need to be mounted to the flange using the supplied M8 socket cap screws. A big bore throttle body should not be used on a manifold that has not been bored to match or exceed the diameter of the throttle body (ie, a 70mm throttle body can be used on a manifold thats bored to 74mm, but not on a manifold thats bored to 65mm). If you intend to bore the manifold yourself, use the supplied plastic gasket to trace out the bore before removing the studs, as shown in Figure 1b. Once traced, remove the gasket and check to see that the traced circle is well defined as in Figure 1c. Next, the studs can be removed. The studs should be removed by threading two nuts onto the stud and binding them together as shown in Figure 1d . Note that a Honda M8 nut uses a 12mm wrench.

Step 1 (Continued):
Next, loosen the stud by using a wrench to rotate the inner nut counter clockwise as shown in Figure 1e. Once the studs have been remove, use a razor to clean any gasket material off of the flange as shown in Figure 1g. Removing gasket material will ensure a better seal after installing the throttle body.

Step 2:
If youre boring your own manifold, a die grinder or high-speed drill can be used with a grinding stone or sanding drum to bore the manifold from its 63mm stock size up to the outside edge of the circle you traced in step 1. Figure 2a shows a manifold being bored; Figure 2b shows a manifold after boring. Once finished, check the port against the gasket to ensure its opened enough. Remember that its better to open the hole up too big than too small. Its very important to

thoroughly clean your manifold after boring it as any aluminum dust left in the manifold could cause damage to your motor. For best results, first blow out as
much dust as possible with compressed air. Next, use a waterhose to thoroughly flood the manifold. Allowing water to flow through the manifold for a while will help to carry out debris that may not have been removed earlier. Make sure the manifold has thoroughly dried before installing it back on your motor.

A Note about boring manifolds:

It should be noted that a big bore throttle body should never be used on an intake manifold that has not had the inlet bored out to match the bore of the throttle body. A setup using a big bore throttle body mated to an OEM sized inlet port will yield lower performance than the OEM throttle body. That said, when boring the inlet on an intake manifold, its best to overbore slightly (about .25-.5mm is sufficient), to prevent the chance of a lip that could create turbulence. While many people will prefer to have a machine shop bore their manifold, if you are familiar with forming metal using a die grinder and sanding drum, you can bore your manifold yourself. If you are hesitant to bore your own manifold, you should consult a machine shop first. Hybrid Racing is able to supply prebored K-Series intake manifolds for an additional charge. Also, note that the use of a 74mm throttle body on a K-series intake manifold dictates that the boring process be a bit more involved. Because of IACV port geometry, boring a PRB, RBC, or RBB manifold to 74mm requires boring a 74mm hole, then welding the IACV passageway shut, and finally reboring the welded area back to 74mm. A 70mm throttle body requires a single boring operation only.

IACV Install:
This throttle body is designed to allow for 3 different IACV mounting options. The IACV mostly serves to stabilize idle after startup and when the AC compressor is engaged. However, its general function is to provide a stable idle at all times. The IACV can be installed in the same orientation as its supplied on an OEM throttle body. In this configuration, you can use the supplied 1/8 NPT nipple to hook up the OEM coolant supply. You may also loop the coolant supply on the block, and not install the nipple. This latter option is normally preferred in performance applications as it allows for lower intake air temperatures. See Step 3 for information

regarding installing the IACV in its OEM orientation.

On some k-swaps where the intake manifold is very close to the radiator, there may be clearance issues that make mounting the IACV in its OEM orientation difficult. The most common problem is that the plug on the harness for the IACV does not have enough room to plug into the IACV. If you wish to retain your IACV functionality but are having these clearance issues, you may wish to rotate the IACV 180 degrees. The IACV can still function properly like this, but you will need to install the supplied 1/8 NPT nipple and run a hose between it and the nipple on the IACV. This setup may produce a slightly rougher idle than the OEM setup, but variation is typically minimal. See Step 4 for information regarding in-

stalling your IACV to provide best radiator clearance.

Finally, some users may prefer to remove the IACV unit entirely. Note that doing so will result in an unstable idle on startup and a generally less constant idle speed than if the IACV was used. Deleting the

IACV without use of an aftermarket ECU like the K-Pro is not possible as the stock ECU cannot run the motor properly without the IACV. On any other throttle body, an aftermarket plate would be needed to
delete the IACV. The Hybrid Racing throttle body, however, has 4 built-in 1/8 NPT ports that allow the

Step 3:
If installing your IACV in the stock orientation, you may opt to run coolant through the IACV (as is done on the OEM throttle body). Alternatively, you can loop the hoses that go from the motor to the throttle body. If you wish to run coolant to the throttle body, you will need to install the supplied 1/8 NPT nipple as shown in figure 3a. You should wrap the threads in Teflon tape or apply a pipe sealant before installing the nipple.

Step 3 (continued):
Thread the nipple in by hand, then firmly tighten it using a 9/16 (or 15mm) deep socket, as shown in Figure 3b. To install the IACV, simply place the OEM rubber gasket in the groove on the throttle body, then bolt the IACV to the throttle body using the (2) supplied 20mm long M5x0.8 bolts and (2) M5 flat washers. The bolts can be tightened using a 4mm allen wrench. When installed, the nipple on the IACV should point away from the intake manifold, as shown in Figure 3c.

Step 4:
Installing the IACV flipped 180 degrees is very similar to how it was installed in Step 3. The key difference is that you cannot run coolant to the throttle body, and you must install the supplied 1/8 NPT nipple. The IACV should be installed with its nipple facing towards the intake manifold. Once bolted to the IACV, the nipple on the IACV should be connected to

Step 5:
If you intend to delete the IACV on your throttle body, you will need to install the (4) supplied 1/8 NPT plugs. (2) plugs should be installed on the backside of the throttle body as shown in Figure 5a. The other (2) plugs should be installed on the underside of the throttle body as shown in Figure 5b. The 1/8 NPT plugs can be tightened with a 3/16 (or 4.5mm) allen wrench. The plugs should be wrapped with Teflon tape or have a pipe sealant applied before installation. If you are not using an IACV on your setup, it will likely be necessary to adjust the idle adjustment screw to allow more air to pass by the butterfly in its closed position. To adjust the idle screw, first youll need to loosen the idle screw jam nut with a 10mm deep socket as shown in Figure 5c and Figure 5d. Note that the yellow Torque Seal thats applied to the idle screw may have adhered the screw and nut together. You may need to use a wire brush or razor to clean the yellow paint off. Once the nut has been loosened, use a 3mm allen wrench to screw the idle screw in as shown in Figure 5e. Once the idle screw has been adjusted to the desired position, retighten the jam nut.

Step 5 (continued):
Note:
Do not loosen the idle screw beyond its supplied position in an attempt to lower the motors idle. During assembly, the idle screw is installed and the butterfly is sealed with a graphite-based sealant. Attempting to close the butterfly beyond its supplied position may increase the risk of the throttle body sticking in the closed position. If you adjust the throttle body and notice sticking in the closed position, open the throttle body fully, gently close it, then tighten the idle screw at least half a turn. Open the throttle plate fully and allow it to slam shut. If it sticks, open it fully, close it gently,

Step 6:
If installing this throttle body on an Acura RSX, the supplied 10mm M6x1.0 bolt can be used to attach the cable guide bracket as shown in Figure 6. Use a 4mm allen wrench to tighten this bolt.

Step 7:
If you dont intend to install the Emissions Solenoid or MAP sensor, you can use the supplied plugs to block off one or both of these ports. If you are using the throttle body on a naturally aspirated setup, simply push the plug into the port you want to block, as shown in Figure 7b. Install the supplied retaining ring (as shown in Figure 7c) if you are using the throttle body on a turbocharged setup. The retaining rings can be installed and removed with a flat head screwdriver or similar tool. Simply press the teeth into the machined groove to install, and pry on the

Step 8:
On the Hybrid Racing K Series throttle bodies, the throttle cable and cruise control cable are flipped when compared to an OEM throttle body. To install the throttle cable, first insert the barrel between through the bracket as shown in Figure 8a. Youll need to open the throttle plate slightly to get the cable into the proper position. The barrel should be inserted into the hole on the throttle cable cam, as shown in Figure 8b. Next, thread the jam nuts on the cable collar as far apart as possible, as shown in Figure 8c. Fit the cable collar into the bracket as shown in Figure 8d. Pull the cable back gently until you feel the throttle cable cam begin to open the throttle plate, but do not adjust it so the throttle plate is opened when the throttle pedal is not depressed. Adjust the first nut so it rests against the bracket, as shown in Figure 8d. Next, tighten the other nut against the bracket as shown in Figure 8e. Use a 12mm open ended wrench to tighten the nut firmly. Install the cruise control cable (if ap-

Step 9:
If you do not intend to use the cruise control feature, you can remove the cruise control cable bracket as shown in Figure 9a. The bracket is held on with two bolts and can be loosened using a 2.5mm allen wrench.

Step 10:
The (4) supplied 25mm M8x1.25 bolts should be used to mount the throttle body to the inake manifold. The supplied thermal gasket should be installed between the intake manifold and the throttle body. The gasket is designed with an outline similar to the throttle body to aid in alignment during installation.

Figure 10a shows the throttle body as installed on a PRB (RSX) intake manifold. For best results, install the throttle body and gasket by first loosely installing the two bolts indicated by arrows in Figure 10a. Next, loosely install the other 2 bolts. Tighten in a criss-cross pattern. You may need to retighten the bolts several times as the plastic gasket will compress as its tightened.

Figure 10b shows the throttle body as installed on an RBC or RBB manifold.

If you have any questions or comments, please email info@hybrid-racing.com or call us at 225-932-9588

Legal Disclaimer
Users assume all cost and risk associated with these or any other items purchased from Hybrid Racing LLC. Parts sold or manufactured by Hybrid Racing LLC may not meet legal requirements for use on public roads. People thinking about purchasing product(s) from Hybrid Racing LLC should check with their local and state authorities for legality. It is the users responsibility to know and comply with all local and federal laws and regulations. Use or installation of Hybrid Racing LLC products may affect user insurance and/or vehicle warranty coverage. It is the users sole responsibility for consequences that may occur due to having the product installed in his/her vehicle. Hybrid Racing LLC assumes no legal responsibilities and/or liabilities, whether to users vehicle, engine, person(s), and/or property(s), that result from the use of, or servicing of a vehicle of which a Hybrid Racing LLC product has been installed/attempted to be installed, or to any other vehicle(s) and/or person(s), regardless of whether or not this product has any involvement directly or indirectly and/or liability, and/or whether or not proper installation has been carried forth. All engines, engine parts and electrical components are for OFF ROAD USE ONLY/RACING VEHICLES ONLY. They are not for or to be used on public roads in the USA. Acquisition of a Hybrid Racing LLC product will act as an acknowledgement of the legal disclaimer stated herein. Hybrid Racing LLC reserves the right to change this disclaimer at any time without any prior consent or notification. Should you need to contact us our details are as follows: Hybrid Racing LLC, 3348 Drusilla Lane, Suite 2C, Baton Rouge, LA 70809 www.hybrid-racing.com