Hi Guys

Today I changes the TB's rubbers and manifolds. I was able to do it without removing the TB assembly or disconnecting the throttle cable. With new parts fitted the throttle is very stiff and will not turn very much at all so when I start the bike the engine is racing and I cannot change the revs. Any ideas pleaase? I've clearly done something but it does not look like the cable is catching or anything else is snagging it.
Thanks
Dave

Have you checked the choke linkage?
Could be somethings have come out of position, or been bent.

Thanks Inge
The choke linkage is fine and moves properly. Maybe te throttle butterfly is bent or otherwise damaged, not sure.

Dave

Try to disconnect the cable, and move the butterflies w/o the cable connected.
Then you should get an idea if it`s the cable or the b/f that is the reason to the problem.

check the clamps around the inlet manifold rubbers (below the tbs )...i had a to adjust a few times to get it right, it would bind the linkages if not setup correctly .

Yeah will do Charlie, I've had a pig of a job getting the clips on, could be one or more is snagging

Indeed, normally the last stub, where the clamp is touching the 'choke' cam if it isn't turned away.

It was a couple of stubs catching on clamp screws. Thanks, it was obvious but I couldn't figure it out. Just spent two hours taking it all apart to sort one clamp.....I have good, sound, advice for anyone wishing to do this work - put the clamps on the TB rubbers before (can I say again BEFORE) you put it all together. Getting the thread started with the clips I used (which are like the OEM ones on the airbox tubes) is nigh on impossble once the rubbers are in place. In the end I used an appropriately sized jubillee clip as I just couldn't get the thread to bite on the monkey-metal clamp - the jubillee clip was longer so no such problem.

Some of you who are similarly afflicted will appreciate that knowing there is one odd clamp on the machine will be a source of irritation for some time to come.......even if no-one else will notice

Best
Dave

oh well ...we do have a friend that notices just about everything that isnt quite right ...dont we blakey ..?

i recon youve set a good trap dave ....

good onya for getting a solution happening

(mutters to self ...really must get my idle position sorted ...had a brain hickup ...must be the tps holding it open a bit )

I went to this site and got the Suzuki clamps that others on the forum have suggested rather than use the one time Oerliker? clamps. They're about the same price as the OEM and work so much easier. You can tighten them up when you get everything back together and make sure nothing is binding.

http://www.powersportsplus.com/parts/detail/suzuki/SP-09402-48207.html

"oh well ...we do have a friend that notices just about everything that isnt quite right ...dont we blakey ..?"

Yeah, but it's for your own good!

touche my friend ...and we're lucky we have you ..

Well there you go. Took her for a ride in the clear light of day and what a difference; smoother and more power. No spilts all the way through the TB rubbers but corrosion between air intake pipe and top of TB No.1 was probably letting in unmetered air. Same cylinder had a lot of corrosion on the injector electrical plug so a good clean up with contact cleaner may have helped things there. All the TB rubbers were split some of the way so good to replace. While I was at it also fitted new manifold stubbs, stub 'O' rings and injector 'O' rings both ends, and injector to rail clips and then put OEM fuel line on feed and return lines.

On the clips - I replaced the OEM (pictured) one-off disposal type below on the air intake tubes (shown before the work was done)...



With the other OEM type that are a solid loop of metal with a screw/captive nut, These were the problematic ones (for me!) to put on once TBs etc were back on as difficult to get the screw to bite as no spare length. If I fitted them and then tried to insert the TB's into the rubbers the TBs did not want to go - too tight. Clips can just be seen below in far right of shot



Not sure what the Suzuki ones look like Brickee - but in another 90K miles I'll defintely be looking to do something differently!

Hope this helps someone?!
Cheers
Dave

blakey wrote:"oh well ...we do have a friend that notices just about everything that isnt quite right ...dont we blakey ..?"

Yeah, but it's for your own good!

Now where is that choke lever cap????

Choke lever cap? I could do with one of them.....

moto-bins...3 pommy pounds. Cheap as chips.

Cheers Blakey, I'm going to have to get one