INSTALLING
1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely.
Gas Tank
2. Install the air filter housing boot and secure with the two hose clamps. 3. Connect the four electrical connectors to the throttle body components. 4. Connect the throttle cable to the throttle body and adjust throttle cable free-play (see Throttle Cable Free-Play in this section); then connect the gasline hose. 5. Install the actuator cover to the throttle body and secure with the two screws. NOTE: The longer screw goes on top.
! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.
REMOVING
1. Remove the seat and side panels; then remove the rear body panel/rack. 2. Disconnect the fuel pump connector and gasline hose from the fuel pump.
6. Connect the battery (positive cable first); then install the side panels and seat making sure it locks securely in place. NOTE: If the throttle body, ECM, TPS, or ISC are replaced, the EFI system must be synchronized. Use the following procedure:
1. With the key off, depress the throttle lever to Wide Open Throttle (WOT). 2. Place the ignition key in the ON position and wait for 10 seconds. 3. Release the throttle lever and wait an additional 10 seconds. 4. Turn the key to the OFF position and allow the gauge to shut off.
XR124A
3. Remove the cable ties securing the vent hose to the frame. 4. Remove the two cap screws securing the gas tank mounting tab to the frame.
Throttle Cable Free-Play To adjust the throttle cable free-play, follow this procedure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster.
XR126A
5. Remove the master cylinder from the mounting bracket; then remove the mounting bracket from the frame.
CF297A
2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever. 3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster.
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