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TR-1 Gold
Throttle Actuator
Installation Instructions
Suzuki 9.9 2005 and Newer
Suzuki 15 HP 2005 and Newer
906-1090-05
1
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Tools Needed: Vise Grips or Similar Pliers Ratchet 12mm socket 10mm socket Extension 6mm internal Hex Bit (Allen) Torque Wrench Hacksaw #1 Phillips screw driver #3 Phillips screw driver Locktite or Similar thread locker Warning! Please Read. This application can be a difficult throttle installation, and requires the use of a Torque Wrench in the installation. Since this engine is so tightly packaged, you may wish to have your Suzuki dealer install this for you. Read through the instruct
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Suzuki Throttle Parts Item # Part Number Description Qty. 1 120-1090-05 Throttle Actuator Assembly. Suzuki 1 3
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Step One: Disconnect motor from battery and or disconnect safety lanyard, to prevent motor from starting during throttle actuator installation Figure 1 Step Two: Remove Cover (cowling) from motor. Figure 2 Step Three: Remove the right side cover as described in the Service Manual. Figure 3 4
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Step Four: Pop the ring off the ball on the drive arm of the throttle actuator that’s located just below the carburetor, as seen in Figure 4. Figure 4 Figure 5 Figure 6 Step Five: Remove the Hex Cap Screw from the actuator as seen in Figures 5 & 6. Remove the Drive arm. 5
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Original Part Modified Part Step Six: Modify drive arm Use a hack saw or similar to remove the left "ear" of the throttle drive arm. See Figure 7. (You can smooth the edges with a file or a piece of sand paper if needed. NOTE: The throttle lever must be free to advance with out touching the lug of the Manual throttle advance. See Figure 8 Figure 7 Step Seven: Reinstall Throttle Drive Arm. Reinstall the throttle drive arm. Be sure the remaining ear is to the right of the LUG & tigh
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Step Eight: Push the ring back over the ball on the drive arm, per Figure 10. Figure 10 Figure 11-A Step Nine: Remove the head bolt, as indicated in Figure 11 & 11-A. Figure 11 7
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Step Ten: Use the removed cylinder head bolt to mount the throttle actuator bracket as shown. Note: Bend the loom holder out of the way temporarily to gain access to the bolt, and then bend it back into place to hold the wire Figure 12 loom & hose in place away from the throttle actuator as shown in Figure 13. Torque bolt 30Nm/21.5 ft.lbs Step Eleven: Remove the nut & lock washer from the throttle arm of the carburetor as seen in Figures 14 & 15. Figure 13 Figure 15 Figure 14 8
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Step Twelve: Put the Nautamatic Throttle Advance bell crank (at the end of the string on the TR-1 throttle actuator) on to the throttle shaft and reinstall the lock washer and nut as in Figure 16. Figure 16 Step Thirteen: Push the actuator shaft (threaded rod) to the fully extended position. Adjust the throttle pull string so there is a 1/16 of an inch bow of slack at full idle and use the screw to lock the string in this position. Figure 17 9
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Step Fourteen: Connect to Electrohydraulic unit at number 2. Be sure to seat this connection firmly. (Other connections per autopilot installation manual.) Figure 18 Step Fifteen: Turn the system on by pressing and releasing the Deckmount button (On/Off switch). The Deckmount will continue to flash for 30 seconds, but the throttle functions will work while it is flashing. With the manual throttle at idle, press and hold the up arrow on the handheld as shown in Figure 19, until the ac
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Step Sixteen: Now test the Idle/Resume function by pressing and releasing the Idle/Res on the handheld. See figure 20. Be sure the Carburetor returns to the full Idle Position. Press the Idle/Res button again, the throttle should advance until the actuator is fully retracted. Figure 20 Step Seventeen: Press the down arrow till the actuator rod is out about 1/4 inch. Press the Idle/Resume to confirm function. Re-adjust string (or parts) if necessary. Return throttle to Idle position
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Step Nineteen: Re-install the lower covers of the motor. Secure Throttle cable in a position where it will not get damaged, cause problems with other parts, or get pinched between the motor frame and the covers. Reconfirm that the throttle returns freely to full Idle. Figure 24 Step Twenty: Route the throttle control wire out of the motor covers and to the Electrohydraulic Unit. Secure the wire and be sure the routing to the box allows for full travel of the motor in both directions plu
