Motor Vehicle Maintenance & Repair Asked by CL40 on September 1, 2020
I am trying to perform a service on my motorcycle. To do this I need to free the throttle bodies so other engine components can move.
The motorcycle is 15 years old. I had expected some difficulty wrenching the throttle bodies off but I did not expect it to be this difficult. I have followed the manufacturer service manual to the exact step and all parts needing to be loosened have been loosened including the lower clamps on the head that hold the boot in place. The boots are supposed to come off with the throttle bodies. There are additional upper clamps that I cannot reach that clamp the throttle body itself to the rubber boot. They are faced in a way that suggests to me (paired with the manual not saying anything about them) that they are not to be messed with.
What I have tried:
In each of these cases I stood over the bike, center to the throttle bodies, and pulled, pushed, and twisted them any way I could. I am actually very tired from the process.
I am posting hoping that someone with more experience than me could give me some advice. I’ve thought about ways to gain mechanical leverage over them. For example, I could rig up something to screw into the throttle bodies where they mate with the airbox and pull them that way. I am afraid, however, of damaging the brittle aluminum threads with a stronger metal/too much force. I’ve also thought about using tiedown straps hooked to ladder for more leverage but the fuel rail is very frail and I dont want to wrap anything near it.
Are there any good tips for getting these things off?
First purchase new ones, then cut them and remove all traces so the new ones seal correctly when you refit.
Correct answer by Solar Mike on September 1, 2020
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