| Author | Message | ||
     Sanchez |
I left Atlanta on the Uly today about 1:00 PM with the intention of making a 3600 mile round trip to Colorado and back. Two hours later the bike stranded me in Alabama. I dismantled enough of the bike to discover that the throttle body butterfly shaft had snapped, then walked over to a Wendy's where I passed 6 hours waiting help to arrive. A friend from work rescued me with my truck at 10:00 PM, and I just got back home. This is the second vacation in a row my Ulysses has wrecked. I'm losing faith. | ||
| Hughlysses |
There are several recent threads about snapping throttle shafts. Seems to occur mostly (all?) on 2006 models. Someone's working up a set of plans that you could take to a local machine shop and have a replacement made. Otherwise, you have to spring ~$400 for a new throttle body. Don't give up yet! | ||
| Dirt |
I feel your pain. I had the same problem a few weeks back. Ended up buying the entire TB assembly. The two dealers I spoke with both stated the shaft and or manifold body were not sold separately. However, a poster Here claims that part #P0013.1AA includes the fuel rail and the TB manifold. Would certainly be a much cheaper fix, if true. The 2007 parts manual lists this part as the fuel rail only so I can't confirm anything, and like I said, two dealers told me I had to buy the entire assembly. Anyway, it's certainly worth looking into. | ||
| Ronmold |
Could the stock breather hoses help lube the throttle shaft? I'm wondering if there's more broken shafts on bikes with the reroute. | ||
| Tootal |
It's not a lubrication problem, it's a flexing problem. After taking Maximum's TB apart I can only surmise that a butterfly screw is getting loose which allows the shaft to flex. Metal can only be flexed so many times before fatigue sets in. They all fail at the screw threads on the butterfly screws. I would think that if the butterfly screws were tight that it shouldn't flex here but if just one loosens or wasn't properly tightened during production, that would allow it to flex there. Maximum's was not an 06 so it is not just them that are the problem. I think I'll check my butterfly screws and make sure they are tight. Again, if anyone wants the blueprint for the shaft PM me. The 06's tps pin is different than the later ones and Maximums is a later one. The pin is 5 degrees off from the plane of the butterfly but I don't know what it is on an 06. If anybody knows this please pass it on as I really don't want to tear mine apart to find out! | ||
| Ronmold |
Maybe remove the butterfly and put a on a lite coat of J-B weld and put it back on, that should keep things "unitized". Note 1: shove small rag down throat before removing shaft screws. Note 2: remove said rag when done or valve train will spite you! I am going to try this! | ||
| Tootal |
The bottom of the screws are drilled out and then swedged to keep them from backing out. I believe that they may not have gotten them tight to begin with or they didn't swedge them enough to keep them from loosening just slightly. I wouldn't recommend removing them as they might twist off on you. Make sure they're tight and leave them alone. If loose then back them out as much as you can without using too much force. Drip some red loctite under the screw head and allow it to run down to the threads and retighten. Let it set up over night and you should be good. | ||
| Hughlysses |
Tootal- I recall reading that said the pin is 90 degrees off for the 2006 throttle shaft relative to the 2007. Another thing that may contribute to breakage- if you don't have any slack in your throttle pull and return cables, the shaft is always going to be under stress. As you open and close the throttle, the shaft would be flexed back and forth which could eventually lead to fatigue failure. That little bit of slack you're supposed to leave so that you can rotate the grip a small amount without moving the throttle may be critical. | ||
| Ronmold |
Thanks for the info, I'll check tightness and leave them alone. | ||
| Etennuly |
Greg, I think that you will find that Maximum's Uly is an '06. So far the only one's that I have seen break are '06's. | ||
| Dirt |
My shaft broke and it is an 2007 Uly. The break was identical to the photo posted in another thread. Right where the screw threads into the shaft. (Message edited by dirt on July 03, 2010) | ||
| Pontlee77 |
Hi guys, You don't need to get the full throttle body as that part you talked about in this post is the part we need, if i'm not wrong is the 07 par so you will need also the TPS sensor as the 07 is 90º turned. In the next week my parts should arrive i'll keep posted to let you know if the parts are right and give you the correct part numbers. | ||
| Xbimmer |
Tootal, PM sent! | ||
| Tootal |
Vern, you are so right. I was thinking the 06 pin was at 3 and 9 o'clock when the throttle was closed. As I was working on the new pin I got it in my head that Maximum's was at 12 and 6 o'clock. That's because I'm looking at it in it's full throttle position.  Thanks for the correction and for not flaming me!    | ||
| Dio |
How is the shaft/butterfly design on a new replacement throttle body? Is it a split shaft with the butterfly sandwiched in the slot? Is there a chance that the new replacement throttle shaft is on needle bearings like the late model unit? If they did a major upgrade, a new assembly might not be a bad way to go. | ||
| Garrcano |
Tootal, thank you for the advice. Checked mine and both are tight. Time will say. P.D. I've used a 2,5 mm allen wrench for head socket screw. | ||
| Dirt |
Dio, the replacement throttle body I purchased had the exact shaft/butterfly design as the one that failed. No differences that I could see and I looked pretty close. The screws joining the two parts are still flared at the bottom to prevent them from backing out. |
