6 - | Throttle body for pivoting fuel tank

1 | Fuel system assembly

2 | Throttle position sensor

3 | Clamp

4 | Hose

5 | Rubber

6 | Heat shrink sleeve

7 | Air temperature sensor

8 | Clamp

9 | Screw

10 | Injector

11 | Intake manifold

12 | Aluminium gasket

13 | Screw

14 | O-ring

15 | Nut

16 | Hose

17 | Clamp

18 | Washer

19 | Union

20 | Gasket

21 | Pressure sensor

22 | Hose

23 | Sensor support

24 | Washer

25 | Screw

26 | Throttle body assembly

27 | Screw

28 | Fuel feed hose

29 | Fuel return hose

30 | Connection hose

Parts catalogue

Intake manifoldS
Fuel System

Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removal of the throttle body

Operation | Section reference
Remove the fuel tank | L 2, Removal of the fuel tank
Remove the airbox | L 7, Removal of the airbox
Disconnect the throttle cable | F 1, Removal of the throttle twistgrip
Disconnect the choke cable | F 1, Removal of the choke cable

Disconnect the connector (A) connecting the main wiring harness to the throttle position sensor (2).
Disconnect the wiring connector (B) connecting the main wiring harness to the air temperature sensor (7).
Detach the air pressure sensor (21) from the throttle body and disconnect the wiring connector (C) from the main wiring harness.
Loosen the clips (17) securing the throttle body to the intake manifolds (11).
Disconnect the wiring connectors (D) connecting the main wiring harness to the injectors (10).
Remove the throttle body assembly (26) from the motorcycle.
If necessary, slacken off the clamps (3) securing the throttle body to the hoses (4) and (16) and remove the hoses.
Undo the two screws (27) to remove the throttle position sensor (2) from the throttle body.
Removal of the fuel injectors
Undo the injector retaining clips (8) with the fuel feed hose (28), fuel return hose (29) and injector connection hose (30).
Undo the screws (25) to remove the injectors from the throttle body, recovering the washers (24).
Refitting the injectors
Lubricate the injector O-rings.
Locate the washers (30) and tighten the screws (25) to the specified torque (Sect. C 3, Engine torque settings).
Refitting the throttle body
If the hoses (4) and (16) were removed, reconnect them to the throttle body with the hose clamps (3), positioning the hoses and clamps as shown in the figure.
Notes
The air temperature sensor (7) is installed on the intake hose of the vertical cylinder (16); to refit, refer to Sect. M 3, Air pressure sensor.
Warning
The hose (16) which mounts the air temperature sensor (17) should be installed on the same side of the throttle body as the position sensor (2).
Notes
The end of the hose with the smaller diameter is to be connected to the throttle body.
Push the hoses fully onto the throttle body, aligning the moulding lines (E) on the hoses with the moulding lines (F) on the throttle body, as shown in the photo.
Tighten the hose clamps to the specified torque (Sect. C 3, Frame torque settings), orienting them as shown in the photo and making sure that they are correctly positioned on the seatings (G) of the hoses.
Locate the throttle body assembly (26) on the motorcycle.
Fit the clamps (17) on the intake manifolds (11) and orient them as shown in the photos.
Orient the throttle body (26) with the race facing the right-hand side (relative to the direction of travel) and insert it fully into the intake manifolds.
Tighten the clamps (17) to the specified torque (Sect. C 3, Frame torque settings), making sure that they do not protrude beyond the locating edges of the manifolds.
Reconnect the wiring connectors (D) connecting the main wiring harness to the injectors (10).
Install the air pressure sensor (21) on the throttle body, insert the tubes of the pressure sensor in the manifold and connect the wiring connector (C) to the main wiring harness.
Connect the wiring connector (B) connecting the main wiring harness to the air temperature sensor (7).
Connect the connector (A) connecting the main wiring harness to the throttle position sensor (2).
If the heat shrink sleeve (6) is to be renewed, slide it over hoses (28) and (29) and seat tight against the clamp (8), as shown in the photo.
Set the hot air blower to 150 °C. While holding the pipes curved, apply heat to “shrink” the sleeve, holding the blower approximately 15 mm from the sleeve. Pass the hot air blower along the sleeve several times (moving continuously from one end to the other) avoiding heating the same point for a prolonged time.
Important
The sleeve should only be heated for the timer it takes to “shrink”; do not carry on heating it beyond this point.

Operation | Section reference
Connect the choke cable | F 1, Refitting the choke control
Connect the throttle cable | F 1, Refitting the throttle twistgrip
Refit the airbox | L 7, Refitting the airbox
Refit the fuel tank | L 2, Refitting the fuel tank

Positioning the injector connection pipe