Booster Plug Install Photos
I installed the booster plug to my 2006 K1200S.
First you remove the seat. Then remove the battery cover. Remove the right and left side tank covers. Remove the two bolts with the spindles that the seat hooks to at the gas tank. These hold the gas tank in place. Now pull up and back on the gas tank creating just enough space to get you hand down to the fuel pump plugs, a vacuum hose, and the gas hose connector to the tank. Remove the electrical plugs and push on the clip that retains the fuel hose and pull the hose away from the tank. Remove the tank and set it aside.
Now you have what is shown in Picture #1 (starting first row, going from left to right)
Picture #2 shows the right side air intake pipe. Remove the one screw at the front opening of the pipe. Remove the retaining clips back at the air filter and remove the pipe.
Picture #3 shows the booster plug installed. The dark blue curved arrow points to the original air temperature sensor. Red arrow is the booster plug. Light blue arrow points to the original sensor connector plugged into the booster plug connector. The metal bracket that I pushed the booster plug behind is highlighted with light green.
Picture #4 shows booster plug connected. Red arrow is original sensor with booster plug connected. Blue is the booster plug. Yellow is the booster plug connector plugged into the factory connector. Purple arrow is the booster plug temperature sensor wire headed to the air intake pipe.
Picture #5 is the right sub-frame to the front/head light. The opening here provides the space to enter into the air intake pipe with the booster plug's air temperature sensor. The red arrow points to the grommet that the air intake pipe nipple engages. I used this for a reference for drilling my hole just back of this nipple so the booster plug temp. sensor had room to stick out of the intake pipe.
Picture #6 is another picture of the sub-frame with the opening space.
Picture #7 shows where I drilled a small hole into the intake pipe. First get a rubber grommet the size that allows the temp. sensor to pass thru snugly because this grommet not only protects the sensor as it passes through the plastic intake pipe but it will hold the sensor in place, all by itself.
Picture #8 shows the booster plug's temp. sensor mounted and pushed into the intake tube through the rubber grommet. Now we just need to mount the intake pipe back onto the bike. Route the wire so it doesn't rub on anything or bind. Use zip ties to hold the wire in place.
Picture #9 is taken from the front of the bike just under the light at the right intake pipe. The arrow points to the booster plug's temperature sensor sticking out in the air flow that goes to the air box and is away from all heat sources. This way the booster plug's temp. sensor "reads" the same air the factory sensor "reads".
Done. Hope this helps.
Last edited by du907; Apr 5th, 2019 at 11:08 pm.