| Author | Message | ||
     Kalali |
Actually I did not break anything, the bike decided to self destruct...Well, sort of, not quite that bad. I was riding home and I noticed the throttle was acting strange and the bike started to cough and sputter and the throttle hanging, etc. Making the long story short, I rode home with difficulty and after a quick inspection I see the gismo which carries the throttle cable was real loose. So I took a few things out of the way and I see the the throttle shaft (the one screwed to the throttle body, one end goes into the TPS and the other end to the cable carrier) broke right off at the right screw. Now here are the questions (and I apologize in advance for not having the parts manual): Is that shaft sold separately? How do you take that intake piece off to have an easy access? I loosened that little bracket underneath the intake and don't see anything holding that piece in place but the assembly is not budging? Sorry about the long post and I am sure this problem is probably considered "trivial" but I am just a shady tree mechanic so give me a little slack. I will study the FSM in the meantime. Thanks in advance. | ||
| Drhacknstine |
Did it break off with no shoulder to mount the throttle linkage to, or simply the nut and thread area of the shaft? | ||
| Essmjay |
Mine broke and stuck open on my S3 at 3/4 throttle in 4th gear going through some twisties. I hung on and rode a mile to a wide spot to pull off and kill the engine. That was 30 miles from home at the end of a 4000 mile ride. You can buy the assembly and install it into the throttle body, then do a TPS reset and you will be good to go. | ||
| Kalali |
It broke off right where the right screw goes into the shaft. Right in the middle of the thread area. The FSM seems to imply that the front portion of the intake (up to and including the rear seal) should slide right out once that little bracket is removed. Mine does not move at all no matter how much I try. Am I supposed to try to "pry" it out right behind the seal? I also don't see anything in the FSM showing the throttle body and/or the shaft. You guys make changing the intake seals sound so easy making me think I am doing something wrong. | ||
| Kalali |
Shane, I can see how it could real dicey if the thing gets stuck at the wrong time and the wrong place. Mine was just hanging by a tread so I managed to get home in one piece albeit a bit scared. I am glad to hear that I can get the small assembly. I am just struggling to get the front part of intake off to get it ready for when I get the part. I don't think I can "slide" that long shaft in the intake without taking that front piece off the bike. | ||
| Oldog |
KAL okey there is a clip on the TB that secures it to the manifold once removed the TB should be removable the "rubber" seal sleeves make apart / together tough the TB is sold as a unit w/o tps.. I would s\have a look in the plug hole and check compression when the tb is replaced. | ||
| Preybird1 |
Kalali You are one luck son of a gun that the little screw didn't hop down the intake. It happened to littlebuggles and ruined his cylinder head. That little front throttle body seal is a "BASTARD" to get apart if it has never been off! I used a little heat to soften the rubber a little. If you must pry it off(if i remember where) On the bottom where that bar screws on and holds it all together you can pry\Spread it there. (Message edited by preybird1 on August 25, 2009) | ||
| 14d |
Seem to be a pretty common problem, is there an updated part? Is it possible to get the entire intake off without pulling the TB or injectors? I tried and couldn't get it, even with the special wrench. | ||
| Preybird1 |
Intake is easy after the first time....EASY is still not fun until the 3rd or 4th time  I can now get it out/in 40 minutes. | ||
| Pkforbes87 |
If you can remove the TB w/o removing the intake manifold, DO IT! Just like Prey said - intake gaskets are a PITA even once you figure out how to get them right. I love the fact that the FSM lists torque values for the manifold bolts even though there's no way on God's green earth to ever get a torque wrench on them. EDIT: My 2000 X1 has allen bolts in all four holes to attach the intake manifold, but the 2002 model has half inch hex heads on the bolts that go into the holes that are accessible from the left side of the engine. If you do have to take your manifold off I highly recommend replacing those two with hex head bolts. It eliminates at least some of the stress of installing the manifold. (Message edited by pkforbes87 on August 25, 2009) | ||
| Kalali |
Thanks a lot guys. PK, I managed to take the throttle body/shaft out after unscrewing the round plate from the broken shaft. Not sure I can put the new one in though. Like Russ said, I was real lucky that the the "little screw" stayed fairly secured even on the broken shaft. I think I will have to take the front part of the intake manifold out and by the way it is fighting, I am pretty sure it has been there since new. Unless somehow I manage to slide the shaft into the TB through the TPS hole and then screw in the plate and secure it on the cable carrier end. Would it be wise to reuse those front intake seals or should I order a new pair? That's if they survive the removal process... Thanks again for all your input. | ||
| Kalali |
Looking at the FSM, it appears that the Throttle Body comes as one piece. So all I need to do is somehow remove and replace that front piece and then guide the throttle cable(s) and reinstall the TPS. By the way, looking at the broken piece, I was trying to figure out how a piece like this would break. There is very little external stress unless something gets lounged inside between the throttle plate and the body (like one of the two little screws) resulting into some major carnage. In my case, my theory is it was caused by backfire. There were two instances when the motor backfired (through the intake) while I was trying to her started and it was not frequent enough to get me too worried. But I think the pressure that was applied from the inside against the throttle plate, specially while it was mostly closed, put too much stress on the shaft and it broke at its weakest spot; right next to the screw. I really can't think of a better root cause for this failure. The fact that the cable bracket was loose and was backing out was because the shaft had broken. Otherwise there is no room for any lateral play inside that TB. I am wondering if I could buy the TB from any of the vendors or it has to come from the dealer. I would also appreciate if anyone has the part number handy. | ||
| Kalali |
Sorry one thing I missed... "I would s\have a look in the plug hole and check compression when the tb is replaced" Could you explain why? | ||
| Oldog |
no metal bits or damage to a cylinder, the front section of the tb has a "stack" there is a clip and rubber ring around the male section, the fit is a friction fit those parts are about 15.00$ replace them.. | ||
| Kalali |
Thanks Oldog. Fortunately, I don't see any metal pieces missing by looking at the broken shaft. The parts fit together exactly when the crack occurred. I am assuming by the "stack" you are referring to the seal thing between the front piece and the intake manifold. | ||
| Oldog |
good that the shaft did not FOD the engine. the stack or "horn" as JR calls it, is IN front of the TB and the TB fits with a clip to the manifold | ||
| Kalali |
I know I was really lucky. When I saw the broken shaft my heart sank...but fortunately the two broken pieces perfectly fit together, not even a spec of metal missing. I ordered the TB and it comes in one piece with the butterfly, shaft and cable bracket all preassembled (PN 29536-99YA). This weekend I will try to pull the TB off the intake and the horn off the TB. I will assess the condition of those two rings/seals once I do this task. It does sound though those seal rings are not reusable so I will probably get a new pair. I am not trying to be cheap but just a bit $ tight these days...Like everybody else probably. | ||
| Essmjay |
What was I thinking... That (replacing the TB) is what I had to do, and what I meant by replacing the assembly. Not really a hard job, just takes longer than it should because of angles and dangles and such. | ||
| Kalali |
Just wanted to close the loop on this... Got the part (the entire manifold assembly from Charlie) and replaced the TB yesterday. Bike runs great, knock the wood! Thanks for all your help. |
