| Author | Message | ||
     2evil4u |
OK. So my Uly has quite a few miles on it. 33,319 as of this writing. I bought it new on 10/7/2006. Last Sunday, on my way to Atlanta, (A trip I make about every six weeks or so.) I noticed the throttle response getting funny. Kinda sticky. And the bike started overheating again like it had during my Vegas trip in May. Then, at my gas stop, I noticed that it wouldn't idle and the throttle was acting really strange. It was not returning to the original home position. (I have a throttle rocker on it, and it is NOT supposed to be sticking straight up at an idle.) I figured, crap, the new idle adjuster screw assembly the dealer installed last month has fallen off and bungled up the rest of the motion. I filled up, managed to get it started, and headed out again. About 2 miles later the motor went to idle and the throttle jammed. So, I managed to coast and lope it off the next exit into an Exxon station parking lot at Exit 100 off I-20 in Bessemer, Alabama. I started to tear it down to see it I could fix it and keep going and the first thing I see is:  That is one of the screws that should be holding the throttle plate to the throttle shaft. It is sitting on the top of the throttle plate loose. I carefully pick it out with needlenose pliers and carry on. The rest of the carnage looks like this:    That is a throttle shaft that has failed at the threaded hole for the attachment screw. I had to get my wife to drive 360 miles in my truck to pick me up. We then drove 360 miles back home, and the next morning I headed back to Atlanta in her Durango to make my class. I dropped the bike off at the shop today but they can't even look at it until 8/1 so I'm going to be bikeless for awhile. I'm figuring minimally, it needs a complete intake manifold. And I need some sort of guarantee that there has been no damage to the motor bearings given the amount of metallic debris the throttle plate created while it was running ••••-eyed. I've seen a few comments about pre-2000 tubers having a problem like this, but I've never heard of any recent ones. | ||
| Dave |
My '06 Ulysses just snapped the throttle body shaft as well this week. Unlike my '99 S3, it broke external to the throttle body so no parts were ingested. I took delivery on mine in Oct '06. Pictures will be forthcoming. Luckily, I've scored big karma points and it happened when coming home from work (20 mi trip)a block from the house. Anyone else? DAve | ||
| Dave |
Holy SH!T -- P/N P0803.1AAA retailing for $462 ~ouch~ updated p/n I suppose DAve | ||
| Dave |
I haven't pulled mine off yet but here is the initial look  | ||
| Lonz |
Mine went out the same way at around 39,000. Luckily it was still under warranty. | ||
| 2evil4u |
Finally looked at mine today. New throttle body on order. Dave, how many miles on yours? If this starts looking more like a trend, (I already know of at least one more early Uly that the throttle broke in Australia.), we might be able to parlay it into an extended warranty on the throttle body and any damage to the motor if it sucks a plate attachment screw. | ||
| Dave |
A mere 21,467 miles and my production date was Sep 05. I ordered one from Hal's. I can't see this being a high stress area. It has to be just bad quality/part supplier. (Like my '99 S3 throttle body) I'm not in warranty. This still doesn't tarnish my excitement/enthusiasm with my Buells. DAve | ||
| 2evil4u |
Mines actually a December '05 build I think. I wonder if the initial run of intakes was iffy? | ||
| Dave |
I agree with that conclusion. Considering the amount of stress applied to it, one would think it's just a run of bad parts. DAve | ||
| Lonz |
Dave In response to your email, I would have to guess a december build date on my bike as well. I can't actually get to the bike since it is currently having the motor rebuilt. | ||
| Bombardier |
How many times have you reset the TPS? Asking as this would seem to be the time when it is under a great deal of load as well as WOT. | ||
| Dave |
Good point but I'd think if this was the case, we'd see many more failures on Lightnings/Firebolts. I've adjusted my TPS once and I typically do not ride WOT. Very rarely WOT DAve | ||
| 2evil4u |
Probably reset the TPS 5 or six times in 19 months/33000 miles. No real force on the shaft during TPS resets as I don't jam it or hold it closed, just let it snap shut. Lots of WOT, but if that can fatigue the throttle shaft in 19 months they really have a design issue. Anybody remember this TSB from NHTSA? I just found it on the NHTSA site and it's in two threads here. I may call Buell and inquire as to what it was really for. http://www.badweatherbikers.com/buell/messages/142 838/257292.html | ||
| 2evil4u |
Finally got it back. They had hell getting the part and then getting it running again. It is running good now though. Unfortunately on my way home from the shop either the regulator or generator died as I now have 12V at the battery but no charging at any engine speed. It goes back in Monday. | ||
| Dave |
Finally got time to pull my throttle body off  DAve | ||
| Dave |
The original throttle body has TBM-5A 2455 The new one is TBM-5B 2997 They appear to be the same though. Anyone with the secret decoder ring? DAve | ||
| Bombardier |
May just be a different quality shaft. Cant be any bigger as it has to fit. | ||
| Jlnance |
Is there anything different about the Uly throttle body, than any of the other bikes. I just searched ebay, and there are Buell throttle bodies list, each around $100. But none of them specifically for a Uly. | ||
| Dave |
Uncertain and a good point. One key fact is the throttle body was revised. Oddly enough... I had a similar incident on my '99 S3. I attempted to go used but I could only find the early production TB part numbers. I didn't want it to happen twice (on the same bike) DAve | ||
| 2evil4u |
My new unit looks like it has slightly smaller diameter screws than the original. That would allow for a little bit more meat to be left in the shaft. | ||
| Tootal |
If this happens to you then PM me and I will send you a modified version that will be stronger. I have them for 06 and 07's. They are $75.00. They come with new screws. Those that are using it say they felt no loss in power. | ||
| Kyleh |
Curious to know from those who have gone through this if it required a reset of the TPS? After utilizing Greg's (Tootal's) shaft to rebuild mine, I find that partial throttle seems fine, but when I try to open her up she falls on her face. I suspect a trip to the dealer may be in my near future. :-/ (Message edited by kyleh on March 21, 2012) | ||
| Tootal |
Reply sent. Yes, a tps reset is required. |
