Throttle Lever and Return Spring. Replacing

THROTTLE LEVER AND RETURN SPRING. REPLACING





1 - 10 Nm (7 ft lb)
2 - Washer
3 - Upper spring plate
4 - Spring for load stop damper
5 - Guide bushing
6 - Lower spring plate
7 - Upper throttle lever
8 - Shim
9 - 10 Nm (7 ft lb)
10 - Washer
11 - Lower throttle lever
- Mark installation position relative to throttle lever shaft
12 - Upper spring plate
13 - Return spring
14 - Lower spring plate
15 - Throttle lever shaft





Removing

CAUTION! When removing and installing the lower throttle lever, make sure that the position of the throttle lever -11- relative to the throttle lever shaft -15- is not changed.

- Check whether idle speed and maximum engine speed are set to specification, and adjust if necessary.
- Disconnect Accelerator Pedal cable.
- Loosen securing bolt -1-. To do so, hold washer -2- tight at outer edge with water-pump pliers and loosen bolt with sharp twist.


NOTE: Loosening the bolt this way ensures that the securing bolt -1- is loosened, instead of the securing nut -9-.

- Loosen securing bolt -1- a few turns and disconnect spring -4- using wire hook.
- Remove upper throttle lever -7- with spring -4-, plates -3- and -6- and guide bushing -5-.
- Remove shim -8-.
- Detach return spring -13-.
- Loosen securing nut -9-.
- Press lower throttle lever -11- onto teeth of throttle lever shaft -15-, remove securing nut -9- and washer -10-.
- Mark installation position of throttle lever -11- relative to throttle lever shaft -15-.
- Remove throttle lever and return spring -13- along with spring plates -12- and -14-.

Installing
- Install return spring -13- together with spring plates -14- and -12-.
- Install lower throttle lever -11- in position marked during disassembly, then install washer -10- and tighten securing nut -9-.
- Tightening torque: 10 Nm (7 ft lb)
- Attach return spring -13-.
- Check idle speed and maximum engine speed (RPM).

NOTE:
- If idle speed differs from the specification only slightly after installation-approx. 200 RPM- the position of the throttle lever has not been changed.
- If the throttle lever is moved clockwise by one tooth relative to the throttle lever shaft, engine speed in the idle position will be approx. 4000 RPM.
- When the throttle lever is moved counter-clockwise by one tooth, the idle speed will be considerably lower-approx. 500 RPM- or the engine will not start and idle without the throttle being depressed.
- In such cases correct the throttle lever position.

- Install shim -8-.
- Install upper throttle lever -7- with lower spring plate -6-, guide bushing -5-, spring -4- and spring plate -3-.

NOTE: Make sure that the guide bushing -5- engages in the shim -8-.

- Install securing bolt -1- with washer -2-, and thread screw in a few turns.
- Attach spring -4- and tighten securing bolt -1-.
- Tightening torque: 10 Nm (7 ft lb)
- Check idle speed and maximum engine speed, and adjust if necessary.