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2009  Yamaha  R6:  How  to  Install  New  Throttle  Bodies  

By: John Fenwick

 

               

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Table Of Contents: Pg. 3………………………..Things You’ll Need Pg. 4………………………. Removing the Seat Pg. 5-6……………………. Removing Plastic Fuel tank shrouds Pg. 7-9…………………….Removing the Fuel Tank Pg. 10-14………………….Removing Air Box/Throttle Assembly Pg. 15-17………………….Separating the Air Box From the Throttle Assembly Pg. 18………………………Swapping the throttle assemblies Pg. 19……………………….Reassembly Pg. 20……………………….Works Cited

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Things You’ll Need:

• 3/8 in’ socket driver • 1/4 in’ socket driver • Allen head wrench kit (assorted sizes) • Phillips head screw drive

*Note: Although these are the most basic tools required, things like socket extensions and an impact driver will the process go much smoother.

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Step One: Removing the Seat

-Locate the two allen head screws towards the rear of the front seat. You will have to pull back the seat’s foam in order to see them. Remember: There are two of these on either side. Remove them both with the proper size allen wrench. The seat will then come off quite easily.

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Step Two: Removing the Plastic Fuel Tank Shrouds

-Remove the small allen head screw located near the rear of the plastic shroud (pictured above).

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Step Two (Cont’)

- After the allen screw has been removed, push forward on the shroud and pull out. It is secured to the front on the fuel tank by two small metal tabs. Do not break them by attempting to pull the shroud straight off. -Repeat process on opposite side.

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Step Three: Removing Fuel Tank

-Remove the allen head screws on either side of the bike. These were revealed when you removed the tank shrouds. (Above)

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Step Three (Cont’) -Remove the allen head screw located at the base of the fuel tank on top of the battery (Pictured Below). This screw is about four inches long.

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Step Three (Cont’)

-Pull fuel tank directly up.

*Note: There are 5 things under the tank that need to be disconnected!! Do not pull on them too hard while lifting the tank!

- Disconnect the following: Green connector, White connector, Main fuel line (from tank and air box), and the small grey vent hoses.

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Step Four: Removing Air Box/ Throttle Assembly

- To Begin, remove all Phillips head screws along edge of air box, and pull air box lid off. (Pictured Below)

*Note: There is a wire coming out of the air box’s lid. You need to trace this wire down to its main connector and disconnect it in order to completely remove the air box.

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Step Four (Cont’) Disconnect all five wires connected to the front of the throttle body. You should be disconnecting the four fuel injectors (grey connectors on light brown fixtures), and the atmospheric pressure sensor (blue connector).

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Step Four (Cont’) -Next, you need to loosen the four large hose clamps around the rubber boot that the throttle assembly is fitted into.

*Note: the hose clamps are difficult to access. Unfortunately, there is no good way to get to them. Persistence and determination always prevails!

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Step Four (Cont’) -Now you should remove the throttle cables from the throttle body assembly. Loosen the cables with an 8mm crescent wrench to gain slack. Then pull the cables from the assembly.

*Note: Again, this step takes some persistence. My fingers were quite raw after battling with the throttle cables for a lengthy period of time. Don’t get discouraged!

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Step Four (Cont’) -After the hose clamps are loose and the

throttle cables are disconnected, firmly pull the entire assembly up and out of the bike. Use good judgment when doing this. It is usually pretty easy to tell when you are about to break something.

*Note: Cover the insides of the motor with a towel! ( pictured above) One small piece of debris in your motor could spell disaster!

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Step Five: Separating the air box from the throttle body -Remove the vapor stacks from the air box. The vapor stacks resemble smoke stacks, in my opinion. They are held on by small “C” shaped clips. Simply pull them out of the clips.

*Note: Use good judgment and try not to break the clips. They are actually quite flimsy.

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Step Five (Cont’) -Once you have successfully removed the vapor stacks, you should see six allen head screws spaced out in the bottom of the air box. These screws are what holds the air box to the throttle body. Remove all of them. (screws pictured below)

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Step Five (Cont’) -Once the screws are removed, the air box should easily come apart from the throttle body. (Pictured Below)

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Step Six: Swap Throttle Body Assemblies

-Simply Swap the old throttle body with

the new one, and attach it to air box.

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Step Seven: Reassembly -Simply follow steps seven through one in reverse order to reassemble. One of the beauties of a motorcycle is that it is assembled just as it is disassembled, and vise versa!

-Now it should be dark outside!

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Works Cited

-Photos taken by Sue Fenwick. -Mechanical work preformed by John Fenwick.