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Butterfly valves keep adjusting

koru77

koru77

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Hi guys,

Bought a '06 gen2 last year with 80k km after not riding for at least 6years. It runs great but i noticed the top butterfly valves keep adjusting after ignition is on, can someone help me to resolve this?

And do you advise on updating the computer to get rid of limiters and the throttle cut-off?

Love to hear opinions and suggestions!

Thx.
 
koru77 said:
Hi guys,

Bought a '06 gen2 last year with 80k km after not riding for at least 6years. It runs great but i noticed the top butterfly valves keep adjusting after ignition is on, can someone help me to resolve this?

And do you advise on updating the computer to get rid of limiters and the throttle cut-off?

Love to hear opinions and suggestions!

Thx.
Click to expand...
I do know the secondary flys cycle through the complete motion just as you turn on the key. This is one of the sounds you hear before you start the bike. I don’t THINK they do any other adjusting after the cycle. Could be wrong. I’ll check my bike when I get a chance.

As for updating the computer…My 09’ has never required an update from Yamaha. However, I have gotten it tuned many yrs ago. For about 600$ they eliminated the fuel cut (so nice), lowered the fan on temp, and worked there magic on the fuel/timing tune. I thought this all was so nice for the enjoyment of the bike. The main thing was the fuel cut though. Getting rid of that was great. Unfortunately, this was on a PCV and before protunerx could flash the ECU and before I knew about guys like Ivans.

Hope that helps.

Anyways, could you elaborate on the flys adjusting after ignition is on?

Edit: Checked my bike. One complete cycle of the secondary flys occurs and that is it.
 
Last edited:
Thanks for the feedback Joe,

So, for the flys this should then only be a single motion, mine keeps repeating over and over, not sure if this stops after the starting of the engine, I'm guessing it does will check this, but currently have the bike stored until season starts again. Can't find anything on this issue so if you have ideas please let me know!

ECU So, it would be good to flash the ECU just for the Fuel cut alone? its really anoying by times.

Thanks,
Maarten.
 
koru77 said:
Thanks for the feedback Joe,

So, for the flys this should then only be a single motion, mine keeps repeating over and over, not sure if this stops after the starting of the engine, I'm guessing it does will check this, but currently have the bike stored until season starts again. Can't find anything on this issue so if you have ideas please let me know!

ECU So, it would be good to flash the ECU just for the Fuel cut alone? its really anoying by times.

Thanks,
Maarten.
Click to expand...
I think it was worth it bc of the fuel cut issue alone. Makes it smooth as the bike should be and much more fun to ride.

Double check the wiring and all connections for damage around the harness/plugs ect. IMG_4948.webp

You may have a damaged servo motor from the crash. Should be #21.
 
koru77 said:
Thanks for the feedback Joe,

So, for the flys this should then only be a single motion, mine keeps repeating over and over, not sure if this stops after the starting of the engine, I'm guessing it does will check this, but currently have the bike stored until season starts again. Can't find anything on this issue so if you have ideas please let me know!

ECU So, it would be good to flash the ECU just for the Fuel cut alone? its really anoying by times.

Thanks,
Maarten.
Click to expand...
Also, try disconnecting and reconnecting battery. Maybe give that servo a little tappy tap. Unplug snd plug back it. It may need to “relearn”.

Trying to come up with suggestions
 
I had a similar problem (this is one of the issues that suddenly appeared after taking my bike to a dealer for valve adjustments).

Go through the testing procedures outlined in the service manual. In my case the servo motor was bad. Maybe you can check the connections to the servo motors, but they are very nicely tucked on the bottom of the servo motor. I don't think they are accessible by any human without removing the throttle bodies. The electrical clip is on the very bottom of the motor, zip-tied to the motor. Here's a pic of the electrical connector on the bottom of the servo (with the throttle bodies removed), and then from above where I got a glimpse of the wires from the TPS Side and from above. I

A new servo motor will run about $275, but when I was looking, the parts guy that I used to work with did a nation-wide search and found two in Japan. 3 to 6 months delivery. He went searching and found one on ebay from a salvage dealer that came off a running 2008. It worked, and saved me $150 and possibly 6 months. All of the parts houses, partzilla, etc., all showed that they are "in-stock"... but they weren't. all backordered.

I would say go through all the testing in the manual... try the easier fixes first. If that doesn't get you anywhere, you may need to go on the search for a new servo... or a salvage servo. If you replace the motor, note that the screws holding it on the TB assembly will be TIGHT and they are phillips screws... lots of pressure to keep the screw head from stripping out.

20211120_11_Plug to servo Under the TBs.webp



20211107_Servo and TPS Top Markup.webp20211107_Servo Motor and TPS Side Markup.webp
 
I did replace the Altenator, because I had the issue with the magnets, luckily no mayor damages, but definitly going to try that, and let you know how it went!

Thx,
Maarten.
 
@Blue Flash Thnx good to lknow I'm not the only one with this issue, Ill Go through the testing procedures outlined in the service manual, ASAP.

Hope its not the Servo Motor...we'll see.

Thx,
Maarten.
 
That was about 5 years ago.
However, the only ones we found were in Japan. There weren't any actually available in the USA.


I found one salvage on ebay. The posting said it came out of a well ruining 08 model, asi recall. I paid about $100 for that one
 
Blue Flash said:
That was about 5 years ago.
However, the only ones we found were in Japan. There weren't any actually available in the USA.


I found one salvage on ebay. The posting said it came out of a well ruining 08 model, asi recall. I paid about $100 for that
Click to expand...
Yes, I will consider used but mine was/is a well running 09 so am concerned about how long a used one will last. Most of the used ones I am seeing are from 07 and 08. Before I do anything I will open it up to see what is going on. The CEL had gone off by the time I got home. I've read that this is typical of the start of the eventual failure which I would expect to be the case.
 
Mine seemed to run well most of the time, but seemed to go back and forth into a low power mode. The check engine light would come on, sometimes go off. The butterflies were not cycling properly. The fault code that kept coming up was Fault Code 48, "sub-throttle servo motor stuck". I ran the diagnostic tests several times and it cycled the flies the first two times, and then stopped working on further tests. Your bike seems to be behaving differently, but if you are seeing the code 48, it could still be the motor. In the diagnostic test, the butterflies should go to full open, stop for 2 seconds, and go to full stop.

The servo motor should be the same from 2006 to 2015 (mine is a 2012). I found several that were listed as "in stock" (partzilla, several other parts houses as well). When I ordered, they were backordered. I went to a dealer that was horrible, but had a great parts guy. He did a nationwide search and there weren't any. Only 2 in Japan in his searches. If you have a Yamaha dealer with a good parts guy, I would recommend trying that approach. Josh at Tejas Powersports in Highlands, Texas did that for me. That's why I went with the salvage. He said that I couldn't even count on the one from Japan getting here in 6 months. I wasn't that comfortable with the used part, but it worked fine and has been working for 4 years.... about 15000 miles so far, no problems. I found mine at denverpowersportsparts for $110. it took a week to get it. IF the problem is the servo motor, salvage parts may be the only way to get it going again if that is the problem.
 
Had a small accident with the bike broke my arm but, everything good, looks like somehow this solved the issue it stops after a few cycles going to run the diagnostics next week just to be sure.
 
My bike went around 3400 more miles before the CEL came back. This time the motor was not running at turn on or in diagnostics mode. I had already bought a whole throttle body assembly off ebay for less than a hundred bucks that came off a pretty low mileage 2008. I swapped the motors and it's back to working correctly again. Hopefully it will last awhile 😀

As mentioned above the screws were very tight especially on my failed one. These are not actually Phillips head screws though. They are JIS (Japanese Industrial Standard) screws. It really helps to use JIS screwdrivers on Japanese bikes.
 
Blue Flash said:
Mine seemed to run well most of the time, but seemed to go back and forth into a low power mode. The check engine light would come on, sometimes go off. The butterflies were not cycling properly. The fault code that kept coming up was Fault Code 48, "sub-throttle servo motor stuck". I ran the diagnostic tests several times and it cycled the flies the first two times, and then stopped working on further tests. Your bike seems to be behaving differently, but if you are seeing the code 48, it could still be the motor. In the diagnostic test, the butterflies should go to full open, stop for 2 seconds, and go to full stop.

The servo motor should be the same from 2006 to 2015 (mine is a 2012). I found several that were listed as "in stock" (partzilla, several other parts houses as well). When I ordered, they were backordered. I went to a dealer that was horrible, but had a great parts guy. He did a nationwide search and there weren't any. Only 2 in Japan in his searches. If you have a Yamaha dealer with a good parts guy, I would recommend trying that approach. Josh at Tejas Powersports in Highlands, Texas did that for me. That's why I went with the salvage. He said that I couldn't even count on the one from Japan getting here in 6 months. I wasn't that comfortable with the used part, but it worked fine and has been working for 4 years.... about 15000 miles so far, no problems. I found mine at denverpowersportsparts for $110. it took a week to get it. IF the problem is the servo motor, salvage parts may be the only way to get it going again if that is the problem.
Click to expand...
Did you throw away your old motor? As I posted earlier I swapped the motor out from the TB I bought and everything is working well. I was curious what the actual problem on the old one was however. The motor ran when tested but it didn't move the butterflies when inserted in the TB I had bought. Upon further inspection it looked like the gear on the shaft of the motor had moved down in the direction of coming off. The gear was spinning with the shaft but looked to be too far down to engage the corresponding gear. I tapped the gear down on the shaft and put the motor back in the TB and it's working like it should now.

I'm curious if you still have your motor around if it runs and what the position of the gear is on the motor shaft.
 
jwarden said:
Did you throw away your old motor? As I posted earlier I swapped the motor out from the TB I bought and everything is working well. I was curious what the actual problem on the old one was however. The motor ran when tested but it didn't move the butterflies when inserted in the TB I had bought. Upon further inspection it looked like the gear on the shaft of the motor had moved down in the direction of coming off. The gear was spinning with the shaft but looked to be too far down to engage the corresponding gear. I tapped the gear down on the shaft and put the motor back in the TB and it's working like it should now.

I'm curious if you still have your motor around if it runs and what the position of the gear is on the motor shaft.
Click to expand...
I think the issue with mine was that the motor was only engaging sporadically, but I don't recall any issues with the gear / shaft. Then again, that has been a few years. I don't know for sure it I tossed the old one or not. I tend to keep things that I don't need... It could be out there taking ups some space in a shelf in the shop...
 
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