Articles & photos
| Back |
XR1200 and XR1200 X throttle shaft repair kit
24-1-2023 - how to repair or replace your XR throttle shaft, with the repair kit
XR1200 and XR1200 X throttle shaft repair kit
for sale in our shop xr1200throttllesolution
OEM Stock HD throttle shaft ( left ) Modified with throttle repair kit ( right )
the repair kit we sell with upgraded bearings
Note!
you must have a heat stripper because all the screws are glued (be careful not to melt the MAP sensor or the TPS sensor) .
It is not necessary to disassemble the cable guide
needed: Loctite 266, Loctite 2701, SF 7063 cleaner, intake seal and injector seals.
!! Please remove the injectors , there is a small amount of fuel in them. There is a risk of fire or explosion and serious injury with the remaining gasoline in the fuel system, and risk of contamination of debris
Why change , off course when broken ! but would be smart to replace this before the throttle shaft breaks , There is a chance if the metal parts sucked in it will or can destroy the engine !
The Stock throttle shaft is very thin at the threads of the throttle screws and makes it very fragile,
as the stock screws can work loose , and popping or back fire can make the construction weak, tightening and put loctite on the screws is not enough and does not solve the fragility of the shaft
Disassembly/
1 / disassemble the injectors first, be careful there is a little gasoline.
2 / You need absolutely to use heat on each screw on the old throttle shaft using the stripper, so you can loosen the loctite on each screw (so you do not break them),
Be carefull not damaging removing the Map sensor and the TPS sensor which are plastic, then repeat the operation on the IAC sensor, you can leave the cable guide on
3 / check the position "closed of your butterfly using a lamp that you pass through the bottom of the pipe (if the axis is not broken otherwise little interest), you will see that it is not completely closed, it will be necessary to put it identically so take a picture !!!!!
4/ Unscrew the butterfly, take it out straight without drilling and without turning it so that the flat edges of it allow its release.
5 / the axis comes out on the gas control side (cable side) - using a wooden wedge with one hand tap on the axis side position sensor and the other hand accompany its exit by pulling a little, it must come out easily with the spring and the bearing; You get this:
Or this if your axis is broken!
6 / remove the clips to recover the thin washer, clean it, pass a small stroke of fine grain sanding paper inside the washer so that it slides on the new throttle shaft ,
do not recover the retaining clip (it is bend ) you have a new one in the kit ...
7/ normally your throttle body is a little dirty , you must clean the throttle as well as the screws to remove the remains of carbon
Finish with sanding paper if necessary 500/600 and 1000, the butterfly 1000
Check with a drill bit of 8 mm or reamer the alignment of the holes of the throttle shaft in the throttle body ,
that there are no burrs before reassembly.
Preparation of the butterfly and Shaft
1) IMPORTANT !! you must prepare your shaft and butterfly , it is a very important step to ensure proper operation, you must sand this on a flat surface with 600/1000 grit sanding paper , to ensure the butterfly is flat and not deformed, the butterfly needs to slide in without forcing as taken the picture off the old position of the butterfly , this needs to go back in the same direction
So part number on the butterfly to the IAC sensor / IAC hole in the throttle body (closing direction)
2 ) legenda of the Shaft -Preparation
A B C
A/ New clips provides, In the photo the original
one is bulging It will slow down the return,
so use the new that come with the kit which is flat
B/ the thin washer you have recovered
C/ put the bearing on the axis
D/ retract the axis by the gas control side
Check that the washer does not protrude from the shoulder of the bearing
Put a wood support underneath the TPS sensor side on the parting plane so as to leave the shaft free to retract the bearing
E/ installation of the bearing on the gas control side , tap in in with high socket
Check that the Shaft rotates freely without hard points, otherwise check your steps to find what is slowing down the movement
3) mounting the butterfly
Turn the Shaft to put the slot vertically and in the middle, milling towards the stop screw (top on photo 1), then insert the throttle vertically part number on the top so that it closes towards the IAC
turn the butterfly without forcing it to take its place! Be careful it can get stuck in the closed position !!
Check the centering
Adjust the position and put the screws without gluing them one by one, then check the free movement, you should not have a hard spot. You get this Once you are sure that everything is ok, you remove one of the two screws,
You degrease with the Loctite SF 7063 then you glue with the Loctite 266 and repeat the operation with the second screw.
Check that everything is free and easy movement , the butterfly can stick a little fully closed
4) Mounting of the throttle cam
You glue and center the pin with Loctite 2701 after degreasing to Loctite SF7063
mount the supplied throttle cam with the return spring,
screw a first time with out loctite to set it up thoroughly on the position pin
check that the throttle comes back and glue the screw to the Loctite 2701
5) Mount the IAC sensor (plug down) with its gasket without forgetting to fold down the cable support, degreasing + gluing the screws to Loctite 2701
The Throttle position sensor ( connector pointing down ) , it is slightly under tension on the Shaft this is normal , turn it front of the screw holes
6) Base adjustment, there must be a little opening of the butterfly
it must not close completely to allow the engine to start and it must not get stuck.
If you open fully and let go of the control at once "when you release the spring". If it gets stuck,
unlock the throttle upside down with a screwdriver handle and gradually reopen the opening, then try again until you get the limit between the jamming point and the free point.
Conversely, a butterfly that is too open will have the effect of slowing down too high even when hot. The ideal setting, is that it touches "almost" in the center at the top facing the hole of the IAC, not always obvious but there is a lateral axial play that is normal (less than original )
If you have any question or would like us to repair your throttle shaft for you, contact us @ info@twinmotorcycles.nl