TB repair kit problem

[red1]

I've just started to repair the left hand TB on my 2002 R1150GS Adv with one of Dan's kits.

Unfortunately the throttle quadrant is of a different design to the one shown in his step-by-step guide.

The nut that holds on the shaft is not on this TB so don't know how to proceed.

Anyone done this with this type of TB?

 

[Ron from BC]

Yikes! I have his rebuild kit for both my TB's however haven't done it yet.....end of the month is my target. I just gave him the year and model of bike (02 GSA like yours) and haven't checked to ensure compatibility.

Maybe I'll start by comparing the Bing numbers in your pic....

Have you been in contact with Dan?

All the feedback about his kits has been good so I'm hoping it's an easy fix for u.

 

[red1]

I'm not saying there's a problem with the kit, just that the example guide has a different TB setup. I believe it's an 1100 TB he uses.
I've emailed Dan so will await his response.

 

[red1]

This is the TB used in his example

 

[Ron from BC]

Understood....I had just pulled up his DIY pics too and had a look. You'll have yours done before I start mine so I'll be interested how you made out and the difference. Apart from resolving the chattering noise I've read reports of it bringing the throttle response back and eliminating some surging.

 

[red1]

Whilst I was waiting for a response I've just upgraded the cam chain tensioner.

10 minute job but worth the £50 for bits.

 

[Ron from BC]

Done that one too....sounds like you're putting the winter season to good use! What's the mileage on your bike......and have you changed your bowden box and cables?

 

[red1]

Just had email from Dan

No problem there

the pics you saw on advrider were from an early 1100 bike, hence the
outer nut. I have changed that design to the one you have now for all TB
repair kits types, so they all look the same now, with an inner M3
thread (that's why the M3 screw and large washer is in for)

You have to punch the old shaft out, using something smaller than 5 mm
in diameter.

 

[Ron from BC]

Phew!

 

[red1]

Drilled the end of the shaft on the quadrant side about 4mm to make it easier to drift out. Success!
Got one of the bushings out with the bolt and wire ploy, but other side is proving a bitch. Starting again this am.

 

[red1]

Fresh coffee, fresh piece of wire and out the 2nd bushing came.

This is the "butchered" end of the shaft. Drilling released pressure on the interference fit to allow it to be drifted out (that's my reasoning anyway)

This is the contents of the kit (both TB's). Left was properly goosed when I bought the bike, right was showing signs of wear, so doing the job right and fixing both.

This is the modified fixing for the quadrant side. Shaft is drilled to accept screw.

Here's a tip when reassembling. When I put the flap back in it didn't seem to sit that well in the body. What i'd done is put it in the wrong way round. It needs to be fitted "shiney side" facing the air-flow into TB.

Also when fitting the flap, tighten the screws so they are in the threads but very slack. Unscrew the quadrant stop right off and flick the quadrant a few times against the return spring. This seems to help the flap to seat much more evenly within the body.

Hope this helps anyone else doing this.