Gen 5 Throttle Body Removal

Oh wise listers:

Over the last week or so, I've been plugging away at changing the
stuck-open thermostat in my '98 VFR. (I'm beginning to suspect that the
bike was built AROUND the thermostat, but I digress...) I've been
working carefully and slowly, following the procedures in the service
manual and I've gotten to the point where I need to remove the throttle
body. It would seem I've come to an impasse...

The manual says to loosen the four ring clamps on the throttle body
insulators between the throttle body and head and then it just says to
"remove the throttle body." Having thoroughly loosened all the clamps,
I simply can NOT get the damned throttle body to separate from the head.
Is there something I'm missing here? Is there some other mechanical
connection between them? ...Or am I just not reefing on things hard
enough? (...And I'm reefing pretty damned hard)

I don't want to break anything. Anyone out there who's done this
already and can give me some much-appreciated advice?


Thanks,
Jake Harsha

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On Friday 19Jan, 2007, at 8:15 AM, Jake Harsha wrote:

> Oh wise listers:
>
> Over the last week or so, I've been plugging away at changing the
> stuck-open thermostat in my '98 VFR. (I'm beginning to suspect
> that the
> bike was built AROUND the thermostat, but I digress...) I've been
> working carefully and slowly, following the procedures in the service
> manual and I've gotten to the point where I need to remove the
> throttle
> body. It would seem I've come to an impasse...
>
> The manual says to loosen the four ring clamps on the throttle body
> insulators between the throttle body and head and then it just says to
> "remove the throttle body." Having thoroughly loosened all the
> clamps,
> I simply can NOT get the damned throttle body to separate from the
> head.
> Is there something I'm missing here? Is there some other mechanical
> connection between them? ...Or am I just not reefing on things hard
> enough? (...And I'm reefing pretty damned hard)
>
> I don't want to break anything. Anyone out there who's done this
> already and can give me some much-appreciated advice?
>
I have not worked on a 5G VFR. That said, the standard advice, when
separating a carb/throttle body from its mounting rubber is:
gently warm the rubber (a hair dryer works well)
use an appropriate lubricant (spray silicone would be my choice, I
think).

HTH,
Johnj


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Jake,
I agree that the bike seems to be built around the 'stat.
:):)
When changing the 'stat on my 99, the TB was VERY difficult to remove. I
wound up blowing warm air on the intake boots with a low power heat gun and
applying even lifting force on both sides of the TB. Seems like I used a
couple of old wooden hammer handles as pry bars, but I can't recall for
sure. I think it would help to have four hands to do this job. Like you, I
was concerned about warping the TB assembly and was amazed at the amount of
force it required, but it finally popped loose with no damage. Just make
sure that everything is loosened/disconnected per the manual prior to doing
this (sounds like you have done this).
John Harrison
Birmingham



-----Original Message-----
From: vfr-bounces@xxxxxx [mailto:vfr-bounces@xxxxxx] On Behalf Of
Jake Harsha
Sent: Friday, January 19, 2007 7:16 AM
To: vfr@xxxxxx
Subject: Gen 5 Throttle Body Removal

Oh wise listers:

Over the last week or so, I've been plugging away at changing the
stuck-open thermostat in my '98 VFR. (I'm beginning to suspect that the
bike was built AROUND the thermostat, but I digress...) I've been
working carefully and slowly, following the procedures in the service
manual and I've gotten to the point where I need to remove the throttle
body. It would seem I've come to an impasse...

The manual says to loosen the four ring clamps on the throttle body
insulators between the throttle body and head and then it just says to
"remove the throttle body." Having thoroughly loosened all the clamps,
I simply can NOT get the damned throttle body to separate from the head.
Is there something I'm missing here? Is there some other mechanical
connection between them? ...Or am I just not reefing on things hard
enough? (...And I'm reefing pretty damned hard)

I don't want to break anything. Anyone out there who's done this
already and can give me some much-appreciated advice?


_______________________________________________
vfr mailing list
vfr@xxxxxx
For subscription and delivery options:
https://lists.cs.wisc.edu/mailman/listinfo/vfr

Friday, January 19, 2007, 7:15:37 AM, you wrote:
> Oh wise listers:

> Over the last week or so, I've been plugging away at changing the
> stuck-open thermostat in my '98 VFR. (I'm beginning to suspect that the
> bike was built AROUND the thermostat, but I digress...) I've been
> working carefully and slowly, following the procedures in the service
> manual and I've gotten to the point where I need to remove the throttle
> body. It would seem I've come to an impasse...

> The manual says to loosen the four ring clamps on the throttle body
> insulators between the throttle body and head and then it just says to
> "remove the throttle body." Having thoroughly loosened all the clamps,
> I simply can NOT get the damned throttle body to separate from the head.
> Is there something I'm missing here? Is there some other mechanical
> connection between them? ...Or am I just not reefing on things hard
> enough? (...And I'm reefing pretty damned hard)

> I don't want to break anything. Anyone out there who's done this
> already and can give me some much-appreciated advice?


> Thanks,
> Jake Harsha




Hi Jake
I did this a while back (last may) and had the same trouble. I
posted a question here just like yours. It does take a good bit of
force. I used a pry bar and carefully pried up on the rear end of the
assembly and it came loose with no damage. Getting the rubber boots
warm will help. Working in winter is a disadvantage if you are not in
a heated garage. Even in May, I used an electric heating pad just
layed on top of the assembly overnight to warm up the boots and make
them more pliable. I am not sure how much good that did but maybe it
helped.
Good luck,
Bob

PS I was also replacing my thermostat as I thought it was stuck open.
Hoever, when I got it out and tested it in a pot of water on the stove
it opened and closed normally. It could be that the act of removing it
got it unstuck.

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Take a piece of wood, and wrap the prying end of a pry-bar with something
that won't mar the throttle body housing. Very carefully, use the wood as a
leverage point, and pry the housing up. There in there pretty good, but only
use as much as is needed. Once you get it off, e-mail us about how to get it
back on. Good luck..

TK
----- Original Message -----
From: "John Johnson"
To: "Jake Harsha"
Cc:
Sent: Friday, January 19, 2007 8:40 AM
Subject: Re: Gen 5 Throttle Body Removal


>
> On Friday 19Jan, 2007, at 8:15 AM, Jake Harsha wrote:
>
> > Oh wise listers:
> >
> > Over the last week or so, I've been plugging away at changing the
> > stuck-open thermostat in my '98 VFR. (I'm beginning to suspect
> > that the
> > bike was built AROUND the thermostat, but I digress...) I've been
> > working carefully and slowly, following the procedures in the service
> > manual and I've gotten to the point where I need to remove the
> > throttle
> > body. It would seem I've come to an impasse...
> >
> > The manual says to loosen the four ring clamps on the throttle body
> > insulators between the throttle body and head and then it just says to
> > "remove the throttle body." Having thoroughly loosened all the
> > clamps,
> > I simply can NOT get the damned throttle body to separate from the
> > head.
> > Is there something I'm missing here? Is there some other mechanical
> > connection between them? ...Or am I just not reefing on things hard
> > enough? (...And I'm reefing pretty damned hard)
> >
> > I don't want to break anything. Anyone out there who's done this
> > already and can give me some much-appreciated advice?
> >
> I have not worked on a 5G VFR. That said, the standard advice, when
> separating a carb/throttle body from its mounting rubber is:
> gently warm the rubber (a hair dryer works well)
> use an appropriate lubricant (spray silicone would be my choice, I
> think).
>
> HTH,
> Johnj
>
>
> _______________________________________________
> vfr mailing list
> vfr@xxxxxx
> For subscription and delivery options:
> https://lists.cs.wisc.edu/mailman/listinfo/vfr
>


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John

The warming of the boots is really helpful in the installation as well. I
cut out a small cardboard box to fit over the boots, cut a hole for the
wife"s hair dryer, set it on low, and let them worm up. Another tool that
will help allot is a hose installation tool from Snap-on/Matco. This is a
point funny shaped tool that allows hooking the edges of the boots when they
bind up, and fold in during installation.
----- Original Message -----
From: "John Harrison"
To: "'Jake Harsha'" ;
Sent: Friday, January 19, 2007 9:02 AM
Subject: RE: Gen 5 Throttle Body Removal


> Jake,
> I agree that the bike seems to be built around the 'stat.
> :):)
> When changing the 'stat on my 99, the TB was VERY difficult to remove. I
> wound up blowing warm air on the intake boots with a low power heat gun
and
> applying even lifting force on both sides of the TB. Seems like I used a
> couple of old wooden hammer handles as pry bars, but I can't recall for
> sure. I think it would help to have four hands to do this job. Like you,
I
> was concerned about warping the TB assembly and was amazed at the amount
of
> force it required, but it finally popped loose with no damage. Just make
> sure that everything is loosened/disconnected per the manual prior to
doing
> this (sounds like you have done this).
> John Harrison
> Birmingham
>
>
>
> -----Original Message-----
> From: vfr-bounces@xxxxxx [mailto:vfr-bounces@xxxxxx] On Behalf
Of
> Jake Harsha
> Sent: Friday, January 19, 2007 7:16 AM
> To: vfr@xxxxxx
> Subject: Gen 5 Throttle Body Removal
>
> Oh wise listers:
>
> Over the last week or so, I've been plugging away at changing the
> stuck-open thermostat in my '98 VFR. (I'm beginning to suspect that the
> bike was built AROUND the thermostat, but I digress...) I've been
> working carefully and slowly, following the procedures in the service
> manual and I've gotten to the point where I need to remove the throttle
> body. It would seem I've come to an impasse...
>
> The manual says to loosen the four ring clamps on the throttle body
> insulators between the throttle body and head and then it just says to
> "remove the throttle body." Having thoroughly loosened all the clamps,
> I simply can NOT get the damned throttle body to separate from the head.
> Is there something I'm missing here? Is there some other mechanical
> connection between them? ...Or am I just not reefing on things hard
> enough? (...And I'm reefing pretty damned hard)
>
> I don't want to break anything. Anyone out there who's done this
> already and can give me some much-appreciated advice?
>
>
> _______________________________________________
> vfr mailing list
> vfr@xxxxxx
> For subscription and delivery options:
> https://lists.cs.wisc.edu/mailman/listinfo/vfr
>


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Here is another tip for installation. There are two L shaped rubber
vent hoses on the underside of the TB that will need to be
reconnected. This is quite difficult unless you have small hands. On
my first try I did not get the hose ends onto their spigots far enough.
This caused one or both of them to bow and cause the throttle
linkage to bind. I had to pull the TB again and fix.

Friday, January 19, 2007, 8:41:36 AM, you wrote:
> John

> The warming of the boots is really helpful in the installation as well. I
> cut out a small cardboard box to fit over the boots, cut a hole for the
> wife"s hair dryer, set it on low, and let them worm up. Another tool that
> will help allot is a hose installation tool from Snap-on/Matco. This is a
> point funny shaped tool that allows hooking the edges of the boots when they
> bind up, and fold in during installation.

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Good news! The heating trick worked like a charm. I set up a couple of
the wife's hair dryers to blow air across between the heads for 15
minutes or so and the Throttle bodies popped right off. =) The old
thermostat was gaping wide open at room temperature. I tested the new
one on the stove top and it worked perfectly. Got almost everything
back together yesterday and now I'm just waiting for a new air filter to
arrive UPS and I'll be able to button it up. Highlights:

*Heat also helps during TB re-installation.

*I used a block of wood and a rubber mallet to pop the throttle body
back on.

*I replaced the vacuum hose that goes to the one-way valve from the
bottom of the airbox with a slightly longer one or I never would've
gotten it re-connected. (Japanese people must have tiny little hands...)


Thanks for the help,
Jake



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