| Author |
Message |
    
Mnrider
| | Posted on Friday, May 14, 2010 - 03:38 pm: | 
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Wonder what the build date is on the bikes those have been braking on.
May 06 build date on my 06. |
Hughlysses
| | Posted on Friday, May 14, 2010 - 03:50 pm: |
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This is the first one I've seen posted here since New12R's broke back in January 2009. You might be able to glean some info by digging through that old thread. |
Mnrider
| | Posted on Friday, May 14, 2010 - 05:26 pm: |
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Thanks for your research on this Hugh. |
Hughlysses
| | Posted on Friday, May 14, 2010 - 08:26 pm: |
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Glad to help. Hopefully my 07 is immune to this problem (fingers crossed)... |
Tootal
| | Posted on Saturday, May 15, 2010 - 11:40 am: |
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Not only is there a weak spot at the threads but they milled out the flat area leaving a sharp corner which is asking for failure. Using an end mill Hugh's slotted shaft has no sharp edges which is desirable. Making that slot is a lot more time consuming than just milling a flat on a shaft so if I make one for Maximum I won't be able to mass produce them at work. I do have to work for the company too! If I get one made I will ask my cousin who owns a shop if he would write a program to mass produce them at which point he could sell them but I have no idea of cost. Making the lock pins was a lot easier than what's required in set up time to fabricate the throttle shaft. My goal is to help out Maximum and/or the gentleman that helped him out. Once I see how much time is involved then I'll see about making spares. My original thought was to make maybe three shafts and if someone broke theirs I could send them one, not make everybody a spare that they are most likely not going to need. This is not a common failure but when it does it really sucks! Bottom line is I can't help anybody out if I don't have a sample to work from so if anybody knows where the broken one is please let me know if I can have it for a template. |
Hughlysses
| | Posted on Saturday, May 15, 2010 - 11:46 am: |
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Tootal- I didn't have anything to do with making that slotted shaft- I just remembered the thread and posted the photo. You should try and contact New12R; since he's already had at least one made, he may be able to help. |
New12r
| | Posted on Saturday, May 15, 2010 - 01:17 pm: |
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Ok fellas, I have the new shaft installed with just over 8k miles on it. It is made of stainless steel and as of right now I am having running issues because of the shaft.
The play from the stock bushing to the new shaft is causing the TPS sensor voltage to fluctuate, in turn the bike is backfiring at low rpm or sustained throttle.
With that said if a new bushing could be made of brass that should help. I can touch the end of the shaft where the throttle cables mount and see the change in the tps voltage live on ECM spy. I am getting almost a 2v change(ranging from 1.6v to 3.4v at idle. same amount of fluctuation at sustained throttle).
The shaft itself was a "prototype" and the guy who made it had about 8 hours into it and never gave me a solid price.
The new shaft is definitely better, but I think the tolerances for machining need to be closer than what I got.
Also note that when I got the new shaft the pin for the TPS was not installed, and getting the old one out was not possible. I used a nail and jb weld to keep the TPS pin in place.
Tootal, I can tear down the bike and send you the TB to see what I got going on if needed. Just PM me. |
Tootal
| | Posted on Saturday, May 15, 2010 - 03:50 pm: |
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New12r, do you know if the shaft diameters are the same and did the throttle body itself sustain damage in the bushing area? The reason I ask is that the new shaft should have been the same as the old one. I'm sure your machinist got that right or at least I hope so. If it's loose in the TB there might have been damage. There are a couple of ways to fix your problem. One, if there is enough material in the bushing area you can ream this out and put a sintered bronze bushing in and it will out live us all. Two, if not then we could ream the holes out to the next convenient size and remake the shaft to fit the new bushing size. I wouldn't want you to remove your TB for me as projects like this are done in small pieces as time allows and I wouldn't want to keep you down for any length of time. If you know the shafts are the same diameter then we can assume that the problem is the diameter of the bushing area. Your best bet would be to remove the TB and give it to your machinist and show him the problem and see if he can bush it or go to a bigger shaft and ream the bushing area to match. Now if you have the old broken shaft and don't mind parting with it I would love to have it to get the dimensions I would need. I'm heading out on a two week road trip on Monday so I won't be around but when I return I would like to start on this. |
New12r
| | Posted on Saturday, May 15, 2010 - 04:14 pm: |
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Without a doubt you can use the old shaft. Shoot me a pm with your addy and I will get it on your way. |
Tootal
| | Posted on Saturday, May 15, 2010 - 06:00 pm: |
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On my way to Georgia next week. I'll stop by and pick it up. PM sent. |
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