Throttle Body stuck

[DZ]

Hi All,

Slow progress on my fixer up - really struggling to get the throttle body out. Pulled the airbox as far as possible, plugged out all hoses, even disconnected the throttle cables (yes, should have rather loosen them on the grip), clamps are out... the airbox was ok to pull out but the TB is stuck AF and I can't move it at all from intake 

Tried prying with screw drivers and picks (rubber moves as far as you can press it, did 2-3mm but scared to break it), soaked with WD40 but no avail. Did check the forum, found barmy's thread RE using metal sheets, I don't know how I could fit that here at all.

Keep in mind, these parts have been untouched in 12 years, took me 10 minutes to pull one of the stuck vac hoses.

Any suggestions? Please see below pics of current state.


Thanks,
Dan

[Hooli]

I twist mine so the throttle bodies are vertical to get room to pull them out. I think I push the back of them down, but not 100% sure. It is a bugger & just as much fun to get them in again. When refitting a smear of red rubber grease can help them slid into place.

[Andre]

Screw the AT sensor out of the air box. Take off the AP sensor. Then use a ratchet type belt (for securing loads - sorry can't think of the right term ATM) to pull and hold the air box towards the back. This will give you enough room to get the metal sheets in once you have separated the TBs from the air intake rubbers.

Where I added the arrow in your pic (TB#1 and #4), I insert M6 bolts with a washer and a nut. Bolts need to be long enough but not too long or you won't get them in the hole. The bolt head goes toward the rubber air intake and the nut/washer towards the TB. Now turn the nut and the TBs will separate from the air intake on the cylinders. This method makes it a breeze to get the TBs off.

To get them back in I use a wooden "stick" to push against the said holes or maybe some other part of the TB (can't remember exactly). If the TBs are aligned correctly with the air intake rubbers they will go in easily.

[Hooli]

Sounds like a lot of faff, I swear & wiggle them for a couple of mins & out they come.

I've been thinking & I think I keep them pushed into the intakes on the engine side as I twist the TB downwards to clear the airbox. As it drops they pop out the engine.

[Andre]

Sounds like a lot of faff, I swear & wiggle them for a couple of mins & out they come.

Lucky you. I wiggled them and swore a lot to no avail. No swearing was needed with the method I described above.

[Hooli]

You're obviously doing the swearing wrong 

[DZ]

Thanks guys,

A combination of that helped!

Pulled the sensor from air box, strapped the air box back and up which gives it a couple more mm wiggle room. Then, a lot more of the right swearing this time and wiggle up/down on the air box side brought it out of the intake.

Was another 20 minutes of correct swearing to get out - don't want to think about assembly yet 

Cheers

[Mick_J]

Thanks guys,

A combination of that helped!

Pulled the sensor from air box, strapped the air box back and up which gives it a couple more mm wiggle room. Then, a lot more of the right swearing this time and wiggle up/down on the air box side brought it out of the intake.

Was another 20 minutes of correct swearing to get out - don't want to think about assembly yet 

Cheers

You have to swear in reverse to get it in 

[Snapey]

Was another 20 minutes of correct swearing to get out - don't want to think about assembly yet 

Cheers

Do the sheet metal bit or risk destroying your rubbers.

[gsxbarmy]

Was another 20 minutes of correct swearing to get out - don't want to think about assembly yet 

Cheers

Do the sheet metal bit or risk destroying your rubbers.

This is the post Pete is referring to - very handy tip  https://gsx1400owners.org/forum/index.php?topic=338.0

[DZ]

Was another 20 minutes of correct swearing to get out - don't want to think about assembly yet 

Cheers

Do the sheet metal bit or risk destroying your rubbers.

This is the post Pete is referring to - very handy tip  https://gsx1400owners.org/forum/index.php?topic=338.0

Thanks mate,

Did stumble on that one when trying to get the TB out in first instance. Definitely going to try that for the assembly...