Triumph Thunderbird Service Manual page 269

Fuel System/Engine Management
Installation
1. If removed, refit the throttle cables to the throttle
body. Ensure the opening cable (identified with an
adjuster midway down its length) and closing cable
are located to the correct cams then fit the cable
locknuts. Tighten to 2 Nm.
Ensure that all the locknuts of both cables are correctly
seated and tightened as a sticking throttle could result
from a loose locknut.
An incorrectly adjusted, sticking or stuck throttle will lead
to loss of motorcycle control and an accident.
2. If the throttle position switch .has been removed,
carry out the adjustment procedure before installing
the throttle body (see page 10-101).
3. Remove the covers from the inlet ports and ensure
that the mating faces are clean.
4. Locate new O-ring seals to the transition pieces.
1.
Transition
piece
2. O-ring
5. Position each transition piece to the cylinder head,
together with the cable guide for the coolant
temperature sensor on the inner, longer, fixing of
cylinder number two. Secure with the screws and
clamping plates and tighten to 9 Nm.
6. Ensure the throttle body clips are in position on the
transition pieces and intake duct, with the screw
heads positioned so that they are under the throttle
body and will face outwards when tightened.
Z Reconnect the ISC stepper motor connector and
position the throttle body assembly to the
motorcycle, feeding the throttle cables, fuel hose and
TPS harness through the frame.
Ensure the throttle body is positively located to the
intake duct and is retained by the clip through its full
circumference. Rectify if necessary as poor engine
performance and engine damage may result from poor
throttle body to intake duct sealing.
8. Push the throttle body into the intake duct and then
the transition pieces. Ensure that each throttle body
is fully seated, and seals each throttle through 360°.
9. Tighten the four throttle body clips, with the screw
heads all facing outwards, to 1.5 Nm.
10. Refit the two throttle to cylinder head fixings. Tighten
to 12 Nm.
11. If fitted, reconnect the evaporative return hoses to
each throttle body.
Note:
• The MAP sensor hoses must not be
swapped between cylinders. If either of the
hoses are swapped over, engine
malfunctions will occur.
• The right hand MAP (Cylinder 2) sensor
hose is marked with a red tape.
12. Refit the MAP sensor hoses to each throttle, ensuring
the right hand MAP sensor hose is connected to the
right hand throttle.
13.
Connect the multi-plugs to:
the throttle position sensor;
each injector, repositioning the boot over each
connector.
14.
Locate the throttles cables to the frame, following the
routing noted during removal. Ensure the cables are
secured in the throttle cable and harness guide.
15. Feed the outer throttle cables through the openings
in the switch cube.
16.
Engage the nipples of the inner cables to the twist
grip.
lZ
Assemble the switch cube, tightening the two screws
to 3 Nm.
18. Attach the cable retainer screw and union to the
switch cube, tightening both to 3 Nm.
Operation of the motorcycle with an incorrectly
adjusted, incorrectly routed or damaged throttle cable
could interfere with the operation of the brakes, clutch
or the throttle itself. Any of these conditions could result
in loss of control of the motorcycle and an accident.
Service Manual - Thunderbird
10.105