Airbox – Throttle Body

6 -	Airbox – Throttle Body

1

2

3

4	Throttle body assembly

5

6

7	Intake manifold

8

9	Pressure sensor

10

11

12

13	Sealing washer

14	Intake manifold

15	Sealing washer

16

17

18

19

20

21

22

23

24

25

26

27

28

Spare parts catalogue


1200 ABS	THROTTLE BODY
1200 ABS	AIR INTAKE - OIL BREATHER
1200 ABS	Fuel System
1200 S ABS	THROTTLE BODY
1200 S ABS	AIR INTAKE - OIL BREATHER
1200 S ABS	Fuel System

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 the airbox and throttle body


Operation	Section reference
Remove the panel	5 - 1, Removing the panel
Remove the seat	5 - 3, Removal of the seat
Remove the front half-fairings	5 - 2, Removing the front half-fairing
Remove the tank covers	5 - 2, Removal of the fuel tank fairings
Remove the fuel tank	8 - 2, Removal of the fuel tank
Removing the blow-by tank	9 - 2.3, Refitting the oil breather tank

Disconnect the connector (A) from the horizontal head air pressure sensor (9).

Undo and remove the fixing screw (17) and remove it from the horizontal head air pressure sensor (9).

Operating on the right side of the vehicle, disconnect connector (B) from the APS sensor.

Operate on the vehicle LH side, disconnect connector (C) of the TPS/ETV motor.

Loosen the clamp (6).

Loosen the clamp (6).

Slide the filter box (1).

Operating on both throttle grip cables (E) and (F), loosen the nuts (D) and, turning the throttle body pulley (G), slide the two throttle grip cables (E) and (F).

Removal of the fuel injectors

Operate on both intake manifolds, disconnect the two connectors (H) of the injectors main wiring.

Operating on both intake manifolds, undo and remove the two fixing screws of the fuel pipe (I).

Operating on both intake manifolds, slide the two injectors (3).

Refitting the injectors

Operate on both intake manifolds, check the presence of the O-Rings (2) and (P) on injectors (3). Apply prescribed grease on O-Rings (2) and (P) of injectors (3).

Insert the injectors in the relevant seats on the intake manifolds.

To avoid damaging the O-Rings, insert the injectors fully home on the intake manifolds by keeping them in line with the relevant seat.

Operate on both intake manifolds, position the fuel pipes fittings on the injectors.

To avoid damaging the injectors O-Rings insert the fittings by holding them in line with the injectors.

Keep the fittings pressed on the injectors, then start and tighten the screws (l) fully home.

Tighten the retaining screw (l) to a torque of 5 Nm ± 10% (Sect. 3 - 3, Frame torque settings).

Connect the main wiring connectors (H) to the injectors.

Disassembly of the airbox – throttle body

Undo the six screws (16).

Remove the throttle body (4) from the filter box (1) with the intake manifolds (14).

Reassembly of the airbox – throttle body

If removed, fit the seals (13) in the seats on the filter housing (1).

If removed, insert the gaskets (15) in the seats (K) of the intake ducts (26).

If removed, refit the intake ducts (14) on throttle body (4) and apply prescribed threadlocker to the screws (5) and tighten them to a torque of 2.5 Nm ± 10% (Sect. 3 - 3, Frame torque settings) following the sequence indicated in figure.

After tightening, visually check that the seals (15), previously fitted on the intake funnels, are still in their seats, and that the intake funnels are perfectly coupled with the throttle body.

Fasten the throttle body (4) to the airbox (1).

Apply the recommended threadlocker to the screws (16).

Position and tighten the fixing screws (16) and tighten them to the torque of 5 Nm± 10% (Sect. 3 - 3, Frame torque settings), following the sequence indicated in figure.

If previously removed, place the horizontal map sensor (9) on the filter box (1) by matching the indicated profiles.

Insert the spacer with collar (18) in the horizontal map sensor hole, by orienting it as indicated.

Fix the horizontal map sensor by starting the screw (17) and tightening it to a torque of 5 Nm ± 10% (Sect. 3 - 3, Frame torque settings).

If the drainage pipe has been removed, fit clamp (27) onto drainage pipe (26).

Fit the drainage pipe (26) by inserting it fully home on fitting (l) on the filter box (1).

Orient the clamp (27) as indicated.

Fix the drainage pipe (26) by tightening the clamp (27).

Smear specified grease on the O-ring (28).

Insert the O-Ring fully home in the relevant seat (L) of the filter box (1).

If removed, refit the throttle grip cable as indicated: insert the opening cable (F) and the closing cable (E) in the corresponding plate seats (L) on the throttle body (4) as shown in figure.

The throttle cables are distinguished by the writings in different colours on them:

-	on the opening throttle cable is a white writing;

-	on the closure throttle cable is a yellow writing.

Insert the bolts (Q) in the corresponding seats of the pulley. Keep oriented as shown in figure, fasten the cables (F) and (E) inserting the nuts (D).

Tighten the nuts (D) to a torque of 2.5 Nm ± 10% (Sect. 3 - 3, Frame torque settings).

Fit the dust caps (S) on the throttle cable sheaths terminals.

Fit the closure throttle cable (E) and the opening one (F) inside the cable grommet (M) present on the filter box.

Refitting the airbox and throttle body

Position the filter box (1).

Operate on the vehicle LH side, connect connector (C) of the TPS/DIV motor.

Operating on the right side of the vehicle, connect connector (B) of the APS sensor.

Connect connector (A) to the horizontal head air pressure sensor (9).

Position and tighten the clamps (6), as indicated, to the torque of 2.5 Nm ± 10% (Sect.3 - 3, Frame torque settings).


Operation	Section reference
Refitting the blow-by tank	9 - 2.3, Refitting the oil breather tank
Refit the fuel tank	8 - 2, Refitting the fuel tank
Refit the fuel tank covers	5 - 2, Refitting the fuel tank fairings
Refit the front half-fairings	5 - 2, Refitting the front half-fairing
Refit the seat	5 - 3, Refitting the seat
Refit the panel	5 - 1, Refitting the panel

Positioning of the airbox drain hose

Positioning the horizontal head air sensor pipe

Positioning the vertical head air sensor pipe