Throttle body rebuild

[Kev95GS]

Howdy all!

My 95 GS needs a new shaft in the right throttle body. I have it off, know the numbers, where to call, etc...

I took the left TB off as well and it doesn't have any play in it so I plan to clean it good and re-install along with a new throttle cable.

What I need is a little guidance on removing the pully and shaft.

I think the cap has to be removed off the other end of the shaft as well. Whats the best way to get it off? :scratch

Any help and/or tips? :dunno

Thanks

Kevin :ear

[JimVonBaden1]

yes, and pliars gently will remove the cap.

Jim :brow

[jingdog]

The cap comes off. Then you remove the nut holding the pulley to the shaft. Then you can slide the shaft out towards where the cap was. Note the circlip on the cap end of the shaft. The new shaft I got for my 96 had the pulley pressed on the shaft. No way to get it off. So you slide the shaft in from the pulley side...and find there no way to get the circlip back on the shaft. I couldnt get anything in the recess to install the circlip. So I just installed the throttle plate with the two screws and used that to hold the shaft in place. Works good so far. (2500 miles) It looks possible to machine metal away from the place where the cap fits on so you can install the circlip. But then the cap wont fit.
I dont know how yours will be but thats how mine was.

[Kev95GS]

So I don't need to remove the pulley?

This is what I am understanding to be the process.

1. Remove the cap and circlip from the outside portion of the TB
2. Remove the nut from the pully side
3. Unscrew the throttle plate and remove
4. Pull the shaft out and replace with the new one.

Is this it?


Thanks

Kevin

[RTNewbie]

So I don't need to remove the pulley?

This is what I am understanding to be the process.

1. Remove the cap and circlip from the outside portion of the TB
2. Remove the nut from the pully side
3. Unscrew the throttle plate and remove
4. Pull the shaft out and replace with the new one.

Is this it?


Thanks

Kevin

Yup. Thats it in the nutshell. I soaked the aluminum cap with liquid wrenck for a day and then heated the cap SLIGHTLY with a small propane torch before gingerly twisting the cap off with pliers. That may not be necessary but it did come right off without mangling it rendering it unuseable.

I opted to replace the entire TB ($133) because my shaft bushing on the pulley side is worn oblong and would likely just wear out my new shaft. Plus I don't like the idea of not securing the shaft end under the cap since the new shaft is pressed into the new pulley ($76). :drink

[billpierce]

complete with pictures

http://forums.pelicanparts.com/showthread.php?t=386137

[jingdog]

On my 96 GS you COULD NOT remove the circlip. There was no way to get to it because that end of the shaft was buried so far in the throttle body. You had to remove the nut and pulley from the other end. Then side the shaft out toward the circlip side. I dont know what other TBs are like but thats how mine was.

[Kev95GS]

On my 96 GS you COULD NOT remove the circlip. There was no way to get to it because that end of the shaft was buried so far in the throttle body. You had to remove the nut and pulley from the other end. Then side the shaft out toward the circlip side. I dont know what other TBs are like but thats how mine was.

That's what I'm finding. I can't get the circlip off becuase of clearance. So it looks like I need to pull the pulley off.

What's the best way to remove the pulley? I don't want to force it or tap on the shaft.

It looks like also if you used a different circlip, the kind that has the holes in it to spread apart, instead of the slip on type, you could get one back on.

Kevin

[jingdog]

You cant remove the pulley as far as I know. You just slip the shaft with the pulley on it into the Tb from the pulley side. If you have metal machined away on the TB from the area where the circlip is you can install the circlip. I have heard of people doing this so it CAN be done. Probably using a dremel tool. Otherwise IME you cant install the circlip. I did not install mine. I assembled the throttle plate into the shaft held by two screws. The plate is a very precise fit in the bore of the TB. Using my (cough) vast mechanical experience I determined the throttle plate will keep the shaft centered in the TB. Thats the way I did it 2500 miles ago and everything is just ducky.
Wait a minute! Now I understand. You CAN remove the origional pulley from the shaft with a nut holding the pulley on to the shaft. Just remove the nut, remove the throttle plate (two screws), remove the aluminum end cap from the circlip side and tap the shaft out towards the circlip side (beat on the pulley side). I forgot to remove the AL cap first and the shaft knocked it off for me. (and put a nice bulge in it)

[Kev95GS]

I got it off by removing the e-clip from the end of the shaft. (I cheated and took it with me to the shop to order a few o-rings and a throttle cable).

David @ Bloodworths in Nashville helped me get it off and said to reuse the old one. You have to kinda distort it and then bend it back.

My concern now is that the housing may be worn as well as the shaft. I'll check it when the shaft comes in and go from there.

Thanks for the help and info. :wave :clap

Kevin

[jingdog]

Youre a better man than me if you figured that out!