[NinjaLife]

Sorry for all the threads every couple so often but fuck I keep running into things I need help with. The shop removed the throttle body assy and I am having the toughest time getting the Assy back into the "lower boots" the manual doesn't give too much help with this part unless i'm looking in the wrong section or missing a vital step.

The problem is that the damn throttle bodies won't slip into the lower boots on the intake. I've pressed down pretty hard and they will not slip in, I've even dabbed a little oil on them to try and help. Any pointers or tips or tricks? The page I'm on is below for reference...All it says is to "Install the holder clamp bolts in the direction as shown."
Am I supposed to tighten the clamps before pushing the throttle bodies down into the boots? That's the only thing I haven't tried...

 

[SkyDork]

No, those clamps hold the TBs in once you get them in. Make sure they are loose. Really loose, but not to the point that the bolts aren't threaded in. Then wiggle the TBs in. Fore and aft and side-to-side. Wiggle while you push. Just like sex. You'll get it.

 

[SpazOnaZX]

....I've had to use grease and a deadblow to get them in.... when they get old/heat cycled they are a real PITA. Lubricant, gentle heat, and start them at an angle and 'rock' them in while you wiggle should do the trick, but having trouble is not out of the ordinary.

 

[SkyDork]

and a deadblow to get them in....

Be careful if using one of these. The sensors on the outside of the TBs are sensitive to impacts. Easy does it on the deadblow.

 

[SpazOnaZX]

Indded... but it was better than setting the bike on fire out of sheer rage after standing on it for the last half our.

Or something like that........

 

[NinjaLife]

Ok well that eases my mind a whole lot! I figured these things were a bitch to put back in lol but I didn't think it was gonna be this bad haha, I will try some of your recommendations especially the gentle heat, I did not think of that one. I'm gonna try my heat gun very sparingly on the low setting to "Soften" the boots. Unless there are any objections.

I did have the clamps loosened all the way like you said SkyDork and I thought I was getting somewhere at one point then one would just pop out boot and freakin' piss me off! Lol, had to leave the bike alone for the past two days.
Thank you guys for the help once again!

 

[SkyDork]

Ok well that eases my mind a whole lot! I figured these things were a bitch to put back in lol but I didn't think it was gonna be this bad haha, I will try some of your recommendations especially the gentle heat, I did not think of that one. I'm gonna try my heat gun very sparingly on the low setting to "Soften" the boots. Unless there are any objections.

I did have the clamps loosened all the way like you said SkyDork and I thought I was getting somewhere at one point then one would just pop out boot and freakin' piss me off! Lol, had to leave the bike alone for the past two days.
Thank you guys for the help once again!

Yes, I object. :badteeth: The problem with a heat gun is there is no way to "sparingly" use it. A hair dryer would be better, but that still would suck IMO. You have to heat all the boots together which you can't really do. Roll the chassis out into the sun and let it sit for a half hour. No need to to get crazy here.

Push down harder while rocking it. If your feet come off the ground while you're pressing down on the TBs, you'll know you're doing it right. Skip the heat gun.

 

[NinjaLife]

Rolling the chassis out into the sun sounds like a much better plan lol, I wasn't too fond of using the heat gun. I'll be waiting until the weekend due to Tropical Storm we're having right now.

 

[SkyDork]

Rolling the chassis out into the sun sounds like a much better plan lol, I wasn't too fond of using the heat gun. I'll be waiting until the weekend due to Tropical Storm we're having right now.

Now you're using that noggin. Colin will be through by tomorrow evening for you. The rain is light down here with no winds. You'll be good to go before the weekend get those things on. :ayyy:

 

[gazx10]

same as spaz, if trouble i use a hard plastic mallet with a little oil and tap them in. tap #4 in, hold it down and come across. piece of cake.
damn if im gonna wrestle with em.

 

[SkyDork]

same as spaz, if trouble i use a hard plastic mallet with a little oil and tap them in. push #4 in, hold it down and come across. piece of cake.
damn if im gonna wrestle with em.

:crackup::notworthy: Whatever works, right Jim? :ayyy: This is a a good way to go about it though. Still not a fan of hammering in my TBs though. But my fat ass provides a lot of weight to push them in with. :badteeth:

 

[gazx10]

well, after a couple minutes with my feet off the ground, anyway i wouldnt shock them much either. little oil light tap seats them across the board. mallet probably weighs 2 lbs, pretty gentle actually kinda seating one at a time with a couple light taps.

 

[donkey-shlong]

Rolling the chassis out into the sun sounds like a much better plan lol, I wasn't too fond of using the heat gun. I'll be waiting until the weekend due to Tropical Storm we're having right now.

Did you ever get your Throttle bodies back in NinjaLife?
I have a Gen 2 with 48k kms on it, spent hours trying to get my throttle body's in the boots, tried every technique i've came across.... I dont want to but i'll likely order a new set of rubber boots and give that a crack

 

[NinjaLife]

Did you ever get your Throttle bodies back in NinjaLife?
I have a Gen 2 with 48k kms on it, spent hours trying to get my throttle body's in the boots, tried every technique i've came across.... I dont want to but i'll likely order a new set of rubber boots and give that a crack

Hey Donkey,

Yes I got them on, I kinda did a combo of all of the things that were recommended in this thread.

It's been awhile but I remember letting the bike sit out in the sun for maybe an hour or so. That along with a little oil dabbed on the throttle bodies and they finally slipped in. It was rough, I only weigh around 140ish soaking wet and there were times where I had my feet off the ground with all of my weight on the throttle bodies trying to push them in. LOL

 

[michael4012]

If you have colortune or some other vacuum balance equipment then every time you remove those bodies 're balance them, if you don't own such equipment then after the kind of force you had to apply to those bodies you must get them synchronized mate. Even if you feel the bike is running ok.

 

[donkey-shlong]

I just got mine in, I spent HOURS trying then I bought a heat gun, put it on the highest setting, warmed them up good and the throttle body went on first attempted... I also used my right foot to put pressure on them while holding the handle bars (not that you need to, but legs are much stronger then arms), and I put a zip tie around the front brake + handle bar so I had something to push against...

TLDR: highly recommend using a heat gun if your struggling