TR-1 Gold
Throttle Actuator
Installation Instructions
Suzuki 9.9 2005 and Newer
Suzuki 15 HP 2005 and Newer
906-1090-05
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Suzuki Throttle Parts
Description
120-1090-05 Throttle Actuator Assembly. Suzuki
Item # Part Number
Qty.
1
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
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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.
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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 &
tighten hex head screw.
LUG
Figure 8
Figure 9
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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
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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
loom & hose in place away from the throttle
actuator as shown in Figure 13.
Figure 12
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
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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
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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 actuator
rod (threaded rod) is fully retracted. It
should move freely without any binding.
Figure 19
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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
by pressing the Idle/Res button.
Step Eighteen:
Use the factory standard throttle
(tiller or remote throttle) to
Figure 21
manually advance and reduce the
throttle setting. See figure 22.
Note: Which ever mechanism
is set for the highest throttle
setting will have control of the
carburetor (tiller, remote throttle,
or TR-1 throttle control.) If your
motor does not idle down fully
when using the autopilot throttle,
check your manual throttle to be
sure it is set at full Idle.
Figure 22
Figure 23
Slack in throttle string at
full idle.
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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 plus tilt. Take care that
the wire does not get kinked, twisted or pinched.
Replace cover (cowling). Re-connect the lanyard and/or
Re-connect motor to battery.
Testing the Actuator Functions:
Please refer to the startup section of your owner’s manual before operating your handheld and running the
throttle actuator.
1. With the outboard in the water, or with a proper coolant flush device connected, start the outboard and
let it warm up to operating conditions. Be prepared to kill the outboard ignition if the idle speed is too
high when the engine starts.
2. With the outboard in idle position make sure there is proper slack in the pull string on the throttle
actuator. If the motor does not go to idle, reposition the string by loosening the pinch screw on the brass
pivot.
3. Using the UP ARROW button on the Handheld verify that the engine rpm’s go up. Using the IDLE/
RESUME button on the handheld verify that the engine returns to idle. Check the throttle up and down
several times along with the idle/res and verify that you don’t have any problems.
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