Throttle Body R and R Tip

[gsxbarmy]

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Throttle Body R and R Trick (courtesy of Snapey)

Removing & replacing the throttle bodies can be a bloody nightmare but a couple of sheet metal pieces makes the job a breeze. The big problem is sliding the air box back. On the right hand side a couple of sensors are in the way & the main wiring loom fouls on the frame.

The offending sensors


And the wiring loom that's in the way


Seeing that the air box won't go back far enough, removing & replacing the throttle bodies without damaging the rubbers & clamps is very difficult. I then remembered that I had a few stainless offcuts lying around. Anything thin & hard will do the job but metal would be best.

300mm x 100mm x 1.2mm stainless 320 x 80 x 1.2 would be ideal.


Don't attempt to remove the throttle cables until the bodies are removed but undoing the cables at the twist grip is an absolute must


After removing the vacuum hoses and electrical connections as described in the manual you can then undo the eight hose clamps holding the throttle bodies. You can then slide the air box back far enough to insert one of the sheet metal pieces between the throttle bodies & air box. If you want you can then slide the second piece between the bodies & manifolds although it's not necessary for removal. You can now remove the cables. I also mark the cables to avoid confusion when putting everything together. To replace the bodies you'll need both sheet metal pieces. Once lined up with the manifold then slide the metal away & fit the bodies to the manifolds. Slide the other piece away & line up the air box




That’s it!