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Buell Forum » Big, Bad & Dirty (Buell XB12X Ulysses Adventure Board) » BB&D Archives » Archive through July 13, 2010 » Broken throttle shaft at 82,000 miles « Previous Next »

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Paul56
Posted on Saturday, June 26, 2010 - 01:39 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

12 miles into my 35 mile commute at 4:30 this morning I felt the engine lay down just a bit. Twisted the throttle a little bit and found it very stiff. Didn't have to close the throttle until getting off the freeway a half mile from work. Engine died, can't turn the throttle at all. Pulled air filter and confirmed shaft broken and one plate screw missing. Inspected shaft carefully just 1200 miles ago at filter change time.
Leaving tomorrow for 2 weeks and won't have internet access for part of the time.
Hopefully someone can find out for me if the custom shaft is available somewhere. Would hate to buy a throttle body and hate even more if it was a back ordered part.
Still grinnin' (kind of like grrrrrrrrr-in)
Thanks all.
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Teeps
Posted on Saturday, June 26, 2010 - 11:19 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Paul56 Posted on Saturday, June 26, 2010
Hopefully someone can find out for me if the custom shaft is available somewhere.


I'd like to know if the custom throttle shaft project has progressed too...

And, if not, I've emailed a local shop to see if they would be interested in making the shaft.

Just costs money...
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Tootal
Posted on Saturday, June 26, 2010 - 02:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Well I took Maximum's TB apart and cleaned it. I removed the shaft and took measurements. I found some 1/2" stainless and threw it in a lathe and turned it to 8mm. .315". I turned one end to 6mm and single pointed the threads for the cable actuator mount. Next will be milling the flats on these threads and then the milling of the slot in the middle. The butterfly is .063" thick so I get to use a 1/16" end mill on a long slot. This will take some time! Anyway, my point is that these are not hard to make but very time consuming. I will talk to my cousin and see if he would be interested in mass producing them and if so what would be the cost. Once I know this I will post the info. I wish I could knock out a bunch of these but they are just too time consuming to make at work. If anyone wants my dimensions PM me and I'll send them to you.
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Natexlh1000
Posted on Saturday, June 26, 2010 - 02:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Are the shafts all different between 2006-2007 and 2008-2010?
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Ronmold
Posted on Saturday, June 26, 2010 - 02:59 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

If these would cost $150-175 ea. they'ed still be worth it considering the throttle body cost, and if done right will last indefinitely!
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Tootal
Posted on Saturday, June 26, 2010 - 03:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I believe, and someone will correct me if I'm wrong, that the 2006/7 are the same and the 2008 and up are the same. The only difference is the TPS pin is 90 degrees different. I also found on Maximum's, the pin is not in line with the butterfly so I will have to figure out the degrees of offset is has.
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Teeps
Posted on Saturday, June 26, 2010 - 04:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Anyone know who makes the throttle body for Buell?
Seems we should be able to source the throttle shaft from the original manufacturer.
Or, perhaps someone can leak the blue print for it...?
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Hughlysses
Posted on Saturday, June 26, 2010 - 05:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

2006 and 2007 are identical except for the TPS pin being oriented 90 degrees differently between the two. Not sure how the 2008-up compare.

Interesting that MOST of the breakages have occurred on 2006 models (knock on wood); maybe the change in the TPS pin orientation has something to do with it. I.E.- the orientation of the pin somehow causes more stress on the 2006 model shafts making them more likely to break.
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Tootal
Posted on Saturday, June 26, 2010 - 05:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Thanks Hugh. I noticed on Maximum's the nut that holds the cable actuator was loose. This may have caused a vibration which helped in the breakage? One other thing was that if one of the screws gets loose it would hurt the integrity of the unit. The butterfly adds strength to the unit but if a screw loosens you loose that and that would allow some deflection at it's weakest point which is the screw hole. The metal at the screw hole is only two spots about a 1/16th in diameter if that. A slotted shaft is more costly but a lot stronger. It will cut some flow down but I think most of us would sacrifice some top end for reliability anytime!
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Tootal
Posted on Sunday, June 27, 2010 - 01:00 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

For those who PM"d me I will send you a blueprint next week as all that stuff is at work. I'll draw it up and get it to you then.
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Paul56
Posted on Monday, July 05, 2010 - 10:32 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tootal- PM sent
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Xcephasx
Posted on Monday, May 16, 2011 - 12:52 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

06 xb12x... same exact thing happened to me last night. i was thinking it was a stuck cable and would be a quick roadside fix. 20 minutes later i was looking at a broken actuator shaft. my primary concern is whether or not the broken piece and the set screw could have found their way into my cylinder, or is it likely that the broken bits are in the bottom of my throttle body?
trying to figure out how to proceed. sounds like the actuator/shaft are hard to get? worth replacing the entire throttle body? do i need to drop my engine?
what's the next step dudes?
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Mstrfrz
Posted on Wednesday, October 26, 2011 - 12:17 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Bump?
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