FUEL SYSTEM (DFI) 3-129

Throttle Body Assy

Idle Speed Inspection/Adjustment

•Refer to the Idle Speed Inspection/Adjustment in the Periodic Maintenance chapter.

Synchronization Inspection/Adjustment

•Refer to the Engine Vacuum Synchronization Inspection in the Periodic Maintenance chapter.

Throttle Body Assy Removal

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. Turn the ignition switch OFF.

Be prepared for fuel spillage: any spilled fuel must be completely wiped up immediately.

CAUTION

Never drop the throttle body assy especially on a hard surface. Such a shock to the body assy can damage it.

•Remove:

Air Cleaner Housing (see Air Cleaner Housing Removal) Primary and Secondary Fuel Hoses (see Fuel Hose Replacement in the Periodic Maintenance chapter)

•Disconnect:

Primary Fuel Injector Connectors [A]

Inlet Air Pressure Sensor #2 Connector [B]

Subthrottle Valve Actuator Connector [C] Inlet Air Pressure Sensor #1 Connector [D] Main Throttle Sensor Connector [E] Subthlottle Sensor Connector [F]

•For the California, Southeast Asia and Thailand models, pull off the vacuum hose.

•Loosen the throttle body assy holder clamp bolts [A].

3-130 FUEL SYSTEM (DFI)

Throttle Body Assy

•Remove the adjusting screw [A] from the clamp.

•Remove the throttle body assy from the throttle body assy holders.

•Remove: Bolt [A]

Holder Plate [B]

Throttle Cable Lower Ends

•After removing the throttle body assy, stuff pieces of lint -free, clean cloth into the throttle body assy holders.

CAUTION

If dirt gets into the engine, excessive engine wear and possible engine damage will occur.

Throttle Body Assy Installation

•Apply a thin coat of grease to the throttle cable lower ends.

•Fit the accelerator cable end and the decelerator cable end into the throttle pulley.

•Install the holder plate [A] securely.

•Apply a non-permanent locking agent to the threads of the holder plate bolt [B], and tighten it.

Torque - Throttle Cable Holder Plate Bolt: 3.9 N·m (0.40 kgf·m, 35 in·lb)

•Install the throttle body assy holder clamp bolts, and tighten them (see Throttle Body Assy Holder Installation in the Engine Top End chapter).

•Turn the throttle grip and make sure that the throttle pulley moves smoothly and return by spring force.

•Run the leads and hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Adjust:

Throttle Grip Free Play (see Throttle Control System Inspection in the Periodic Maintenance chapter)

Idle Speed (see Idle Speed Adjustment in the Periodic Maintenance chapter)

FUEL SYSTEM (DFI) 3-131

Throttle Body Assy

Throttle Body Assy Disassembly

1.Throttle Body Assy

2.Subthrottle Valve Actuator

3.Main Throttle Sensor

4.Subthrottle Sensor

5.Primary Fuel Injectors

6.Delivery Pipe Assy

CAUTION

Do not remove, disassemble or adjust the main throttle sensor, subthrottle sensor, subthrottle valve actuator, throttle link mechanism and throttle body assy, because they are adjust or set surely at the manufacturer. Adjustment of these parts could result in poor performance, requiring replacement of the throttle body assy.

•Remove the throttle body assy (see Throttle Body Assy Removal).

•Remove the screws [A] to pull out the primary fuel injectors [B] from the throttle body assy together with the delivery pipe assy [C].

NOTE

○Do not damage the insertion portions of the injectors when they are pulled out from the throttle body.

3-132 FUEL SYSTEM (DFI)

Throttle Body Assy

•Pull out the primary fuel injectors [A] from the delivery pipe assy [B].

NOTE

○Do not damage the insertion portions of the injectors when they are pulled out from the delivery pipe assy.

CAUTION

Never drop the primary fuel injector especially on a hard surface. Such a shock to the injector can damage it.

Throttle Body Assy Assembly

•Before assembling, blow away dirt or dust from the throttle body and delivery pipe assy by applying compressed air.

•Replace the O-rings [A] of each primary fuel injector [B] with new ones.

•Apply engine oil to the new O-rings, insert them to the delivery pipe assy [C] and confirm whether the injectors turn smoothly or not.

•Replace the dust seals [A] with new ones.

•Apply engine oil to the new dust seals.

•Install the primary fuel injectors along with the delivery pipe assy to the throttle body.

•Tighten:

Torque - Delivery Pipe Assy Mounting Screws (Throttle Body Assy): 3.43 N·m (0.35 kgf·m, 30 in·lb)

•Install the throttle body assy (see Throttle Body Assy Installation).