11.122 ServiceManual-RocketIll

9. Releasethefixingsecuringtheintakeducttoitsbracket.Removetheduct.

1. Intakeduct

2. Fixing

1o.Iffitted,disconnectthesmalldiameterevaporativesystem returntubesfromthe baseofeachthrottle.

11. Disconnectthrottlecablesfromthrottlelinkageasdescribedonpage11.117.

12. Disconnecttheelectricalmulti-plugsfrom;

• bothofthethrottlepositionsensors,

• theidlespeedcontrolsteppermotor,

• thesecondthrottlesteppermotor,

• theinjectors.

11. DetachtheMAPsensorhosesfromthefour-wayconnectorabovethecamcover.

12. Releasethetwofixingssecuringthethrottlebodiestothetransition piecebrackets.

13. Releasetheclipssecuringthethrottlebodiestothetransitionpieces.

1. Throttlebody

2. Clips

16. Raisethethrottlebodiesfromthetransitionpiecesand,feedingthefuelhoseandwiringpasttheframeetc.removethethrottlebodiesfromtheengine.

17. Removethescrewssecuringeachtransitionpiecetothecylinderhead.

18. Removethetransitionpieces anddiscardthe'O'-ringseals.

Note:

• Collectthethrottlebodybrackets from thetransitionpiecesforthrottles1and3.

Covertheinlet portstoprevent theingressofdirtandotherobjects.

Installation

1.Removethecoversfromtheinletportsandensurethatthematingfacesareclean.

2.Locatenew'O'-ringsealstothetransitionpieces.

1.Transitionpiece

2.0-ring

3. Positioneachtransitionpiecetothecylinderhead,togetherwiththebracketsoncylinders1and 3.Tightenthescrewsto12Nm.

4. Positionthethrottlebodyassemblytothetransitionpieces,feedingtheMAPsensorhoses,fuelhosesandsensor/motorcablesthroughtheframe.Pusheachthrottlebodyintoitsrespectivetransitionpiece.Ensurethateachthrottlebodyisfullyseated.

5. Tightenthethrottlebodyclips,withthescrewheadsallfacingrearwards,to1.5Nm.

Note:

• Ensurethethrottlesseatcorrectlyinthetransitionpiecesandsealeachthrottlethrough360degrees.

Fitthethrottlebodytotransitionpiecebracketfixings,tighteningthemto6Nm.

_- ServiceManual-RocketIll

11.123

3. OnCaliforniamodels,reconnectthe evaporativereturnhosestoeachthrottlebody.

1

3. Connectthemulti-plugsto;

• bothofthethrottlepositionsensors,

• theidlespeedcontrolsteppermotor,

• thesecondthrottlesteppermotor,

• eachinjector.

3. Connectandadjustthethrottlecablesasdescribed on page11.118.

1.Intakeduct

2.Fixing

12.Refittheintakeplenumtothethrottlebodiesandintakeduct.Tightenallhoseclips.

3. FeedtheMAPsensorhosesbacktothefour-way

connectorandreconnectthem.

3. Position theintakeducttoitsbracketandalsototheintakehose.Securetheintakehosewithitsclip.

1. Intakeplenum

2. Intakeduct

3.Clips

13.ReconnecttheMAPandairtemperaturesensorconnections.

^11.124 SeiviceManual-RocketIll

InjectorsandFuelRail

Ensuretheplenumispositivelylocatedtothethrottlebodiesandintakeductandisretained bytheclipsthroughtheirfullcircumference.Rectifyifnecessaryaspoorengineperformanceanddamagemayresultfrompoorplenum/ductsealing.

14. Supportthetank,removeandstowthetankprop,then lowerthetanktotheframeandsecureitasdescribedonpage11.99.

15. Refittheintakecoverasdescribedonpage

11.99.

16. Reconnectthebattery,positive(red)leadfirst.

17. Refittherider'sseat.

Removal

1. Removerider'sseat.

2. Disconnectthebattery,negative(black)leadfirst.

3. Removethethrottlebodiesasdescribedonpage

11.122.

2. Removethethreescrewssecuringthefuelrailandfuelhoseto thethrottlebodyassembly.

1^".^''Fuelrail

2. ScrewsNote:

   • Thefuelrailandinjectorsareremovedfromthethrottlebodiestogether.

5. Gently easethefuelrailandinjectorsupwardstoreleasethemfromthethrottles.

1.Fuelrail

2.Injectors

ServiceManual-Rocket111

11.125

6. Easetheclipsfromthetopofeachinjector.

""'

1.Clips

2.Injectors

7. Easeeachinjectorfromthefuelrail.

8. Recovertheupperandlower0-ringsfromeachinjector.

Assembly/installation

1. Fitnew0-ringstoeachinjector.

2. Locateeachinjectortothefuelrail

3. Fittheinjector/fuelrailassemblytothethrottlebody,orientatingeachinjectorsuchthattheelectricalconnectionisfacingupwards(towardsthesecondbutterfly).

4. Retaineachinjectorwiththeclipsremovedearlier.

5. Fitandtightenthefuelrailscrewsto5Nm.

6. Refitthethrottlebodiesasdescribedonpage

11.123.

7. Reconnectthebatterypositive(red)leadfirst.

8. Refittherider'sseat.

PrimaryThrottlePotentiometer

Note:

• Theprimaryandsecondarythrottlepositionsensorsaredifferentandmustneverbetransposed.Foreaseofidentification,theprimarythrottlepositionsensorhasashorterconnectorcablethanthesecondary.

Removal

1. Removetherider'sseat.

2. Disconnectthebattery,negative(black)leadfirst.

3. Removethethrottlebodiesasdescribedonpage

11.122.

4. RemovetheTorxscrewsecuringtheprimarythrottlepositionsensortothethrottlebody.

cbti

1.Primarythrottle positionsensor

5. Turnthesensoranti-clockwiseanddetachitfromthethrottlebodybygentlypullingoutwards.