Throttle body

6 -	Throttle body

1	Complete fuel system assembly

2	Throttle position sensor

11	Complete throttle body

12	Hose coupling

13	Stepper motor

Screw

15	Delivery hose

16	Return hose

Hose

Parts catalogue


1100	INTAKE MANIFOLDS
1100S	INTAKE MANIFOLDS

Caution

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 seat	E 3, Removing the seat
Remove the airbox	L 7, Removing the airbox
Disconnect the throttle control cables	F 1, Disassembling the throttle 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).

Disconnect the main wiring harness connector (D) from the stepper motor (13).

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

Removing the throttle position sensor

Note

This operation can even be performed with the throttle body positioned on the vehicle.

The throttle position sensor (2) is fitted to the MASTER (vertical cylinder) throttle on the right side of the throttle body. To remove it from the throttle body, loosen the two screws (5).

Removing the injectors

Loosen the clips (7) that hold delivery hose (15), return hose (16) and injector connection hose (9) to the injectors.

Unscrew the screws (6) to release the injectors from the throttle body. Collect the washers (4).

Refitting the injectors

Grease the O-rings of the injectors.

Fit the washers (4) and tighten screws (6).

Removing the stepper motor

The stepper motor (13) is mounted in the throttle body central section: loosen screws (14) and disconnect tubes (E) from throttle body to remove it. Please refer to Sect. M 3, Stepper motor about its operation.

Refitting the stepper motor

Fit tubes (E) on throttle body.

Position the motor with its support onto throttle body; start the screws (14) in its thread.

Tighten the screws (14).

Refitting the throttle body

If you have removed the hose couplings (12), refit them to the throttle body and lock them with clamps (3). Correct position of hose couplings and clips is shown in the figure.

Note

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 (F) visible on the hoses with those (G) 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 groove (H).

Fit clamps (3) onto intake manifolds (A) and position them as shown.

Orient throttle body (11) with the pulley to the right (with respect to riding direction) and insert it fully home into intake manifolds.

Tighten the clamps (3) to the specified torque (Sect. C 3, Frame torque settings), ensure that they do not come out of the manifold edges (E).

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

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

Connect the main wiring harness connector (D) to the stepper motor (13).

Caution

If the throttle body is replaced, it is necessary to perform a “Zero setting the throttle position sensor (TPS)“ as described in Sect. D 5.


Operations	Reference - See Section
Connect the throttle control cables	F 1, Reassembling the throttle control
Refit the airbox	L 7, Refitting the airbox
Refit the seat	E 3, Refitting the seat

Stepper motor positioning