Throttle body for plastic tank

6 -	Throttle body for plastic tank

1	Complete fuel system assembly

2	Throttle position sensor

3

4	Hose coupling

5

6

7

8

9

10

11	Complete throttle body

12

13

14

15

Spare parts catalogue


Inlet dict
Fuel system

Bold reference numbers in this section identify parts shown in this exploded view diagram. These parts do not appear in the figures near the text.

Removing the throttle body


Operations	Reference See Section
Remove the fuel tank	L 2, Removing the fuel tank
Remove the airbox	L 7, Removing the airbox
Disconnect the throttle control cable	F 1, Disassembling the throttle control
Disconnect the choke control cable	F 1, Removing the choke control

Loosen the clamps (3) securing throttle body to intake manifolds (A).

Disconnect the main wiring harness connector (B) from the throttle position sensor (2).

Disconnect the main wiring harness connectors (C) from the injectors (8).

Lift the complete throttle body (11) from the frame.

If needed, loosen the clips (3) holding the hose couplings (4) to the throttle body and remove the hoses.

Unscrew the two screws (12) to release the throttle position sensor (2) from the throttle body.

Removing the injectors

Loosen the clips (7) that hold delivery hose (9), return hose (13) and injector connection hose (6) to the injectors.

Unscrew the screws (14) to release the injectors from the throttle body. Collect the washers (15).

Refitting the injectors

Grease the O-rings of the injectors.

Position the washers (15) and tighten the screws (14) to the specified torque (Sect. C 3, Engine torque settings).

Refitting the throttle body

If you have removed the hose couplings (4), refit them to the throttle body and lock them with clips (3). Correct position of hose couplings and clips is shown in the figure.

Fit the hoses with the smaller diameter end facing the throttle body.

Push the hoses fully home onto the throttle body. Line up the mould parting lines (D) visible on the hoses with those (F) of the throttle body.

Tighten the clips to the specified torque (Sect. C 3, Frame torque settings). Position them as shown in the figure and make sure they do not slip off the hose coupling grooves (E).

Position the complete throttle body (11) to the motorcycle.

Place the clips (3) in their grooves in the intake manifolds and tighten to the specified torque (Sect. C 3, Frame torque settings).

Connect connectors (C) connecting main wiring harness to the injectors (8).

Connect the main wiring harness connector (B) to the throttle position sensor (2).

Should the throttle body or throttle position sensor be replaced, reset the throttle body as specified under "Zero setting the throttle position sensor (TPS)" (Sect. D5).


Operations	Reference See Section
Connect the choke control cable	F 1, Refitting the choke control
Connect the throttle control cable	F 1, Reassembling the throttle control
Refit the airbox	L 7, Refitting the airbox
Refit the fuel tank	L 2, Refitting the plastic fuel tank

Injector connection hose routing