6 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
 Spare parts catalogue
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but can be found in the exploded view diagram.
Removal of the throttle body
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).
Disconnect the connector (C) connecting the main wiring loom to the stepper motor (31).
Disconnect the air pressure sensor (21) from the throttle body and detach connector (D) from the main wiring harness.
Release the clip clamp (E) and remove the delivery and return hoses from the frame.
Loosen the clips (17) securing the throttle body to the intake manifolds (11).
Disconnect the wiring connectors (F) connecting the main wiring loom 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.
Refit on injectors: fuel feed hose (28), fuel return hose (19) and injector connection hose (30), then tighten them using ties (8).
Fit washers (24) and tighten screws (25) to the specified torque (Sect. C 3, Engine torque settings).
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.
 
Removal of the stepper motor
The stepper motor (31) is installed in the central part of the throttle body:
To remove it, unscrew the two screws (32) and disconnect the hoses (G) from the throttle body.
Refer to Section M 3, Stepper motor for details on its operation.
Refitting the stepper motor
Connect the hoses (G) to the throttle body.
Locate the stepper motor (31) with its support on the throttle body, fitting the screws (32).
Tighten the screws (32).
Refitting the throttle body
If the hoses (4) and (16) were removed, reconnect them to the throttle body with the clamps (3), positioning the hoses and clamps as shown in the figure.
Note
The air temperature sensor (7) is installed on the vertical cylinder manifold (16); refer to Sect. M 3, Air pressure sensor for its installation.
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).
Note
The end of the hose with the smaller diameter is to be connected to the throttle body.
 
Take couplings (4) and (16) fully home on throttle body, ensuring the mould parting lines (M) of couplings match with the right-hand edge of throttle body sockets (H), as shown below.
Tighten the clamps to the specified torque (Sect. C 3, Frame torque settings), complying with the positioning shown in the figure and ensuring they do not pop out of their seats (L) on couplings.
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 edges of the manifolds.
Reconnect the wiring connectors (F) to connect the main wiring loom to the injectors (10).
Install the air pressure sensor (21) to the throttle body, fit pressure sensor hoses to manifold and connect connector (D) to main wiring harness.
Connect the connector (C) connecting the main wiring loom to the stepper motor (31).
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).
Fasten the delivery and return hoses to the frame by means of the clip clamp (E).
 
Positioning of the hoses on throttle body