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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » Archive through July 18, 2011 » What have I done?? Urgent help needed please. « Previous Next »

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Jonny_fantastic
Posted on Wednesday, May 18, 2011 - 05:04 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Following on from my last post (engine stalling / wont idle / revs climbing and dropping), I shorted out pins 1 and 2 and got error codes 36 (fan) and 21 (active muffler control). The 36 code makes sense as I replaced the fan less than 50 rides ago, so is probably a historical code, and it blew a fuse a few weeks ago (brake/horn/muffler) so I was thinking error 21 might be something to do with it.

Right then, following the diagnostics flow chart in the manual says
step 1: remove airbox cover etc - I did that.
step 2: With the throttle in the wide open position, ignition on, run/stop on, does the actuator cycle smoothly? - I did that and nothing happened.
ok, I turned the key off, released the throttle, turned it on again and tied to start it. It made a 'click click click' noise as it started, fired up and died, but my throttle grip wont move!!!! It starts up, runs for a second or 2 and then dies.

Please help as I only followed the manual now its worse than it was before and I am stuck without transport.
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Akbuell
Posted on Wednesday, May 18, 2011 - 10:54 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

First, check your battery for good health, and make sure the batt cables are connected tightly. Low voltage/bad grounds can cause strange issues.

If the throttle grip won't move now, go over the things you did before re the airbox, ect. Sounds like something got pinched or crimped on reassembly.

And it might do to check about on the web for like-minded folks in your area. I believe there is a strong Buell community over there.

Hope this helps; let us know how it is going, Dave

(Message edited by Akbuell on May 18, 2011)
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Jonny_fantastic
Posted on Thursday, May 19, 2011 - 07:21 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

1 of the bolts on the throttle butterfly has sheared off and dropped into the engine. Guess thats FUBAR-ed then.
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Akbuell
Posted on Thursday, May 19, 2011 - 08:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ouch!!!! Sorry to hear that. Explains a lot about the running issues.

Pull your spark plugs and have a look. With luck (to make the best of a bad situation) only one will show signs of damage. Meaning damage to only one cylinder. A leak-down test is also in order.

Looks like at least one cyl head has to come off ......
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Reepicheep
Posted on Thursday, May 19, 2011 - 09:02 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

How big are those bolts? Maybe it just passed through like a big ol kidney stone. : )

Is the butterfly in place still? Or is it flopping around?
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Al_lighton
Posted on Thursday, May 19, 2011 - 09:46 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Take a much closer look. I'd be willing to bet that the bolt didn't shear off, but that your throttle shaft has broken at the bolt. I've been seeing that with increased frequency recently.

The bad news is that the throttle shafts aren't purchasable by themselves, there is no individual part number for it. THe only OEM solution is to replace the entire throttle body ($$).
There is a company in Cali (BC Gerolamy, http://www.bcheads.com/) that does throttle body boring that has made one, but I don't think it is for general sale at this time.

Look closer at that shaft, and if it is cracked, contact BC Gerolamy and see what they can do.

I have a broken shaft here, it may be time to crank up the CAD system and start making that part.
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Jonny_fantastic
Posted on Thursday, May 19, 2011 - 09:48 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The butterfly is still in place, but there is no way in the world that my luck would let the bolt pass straight through, never happen - think about it, this is a guy that recently spent 200 on a starter and alternator for his van, only to have the head gasket give up a month later, this is a guy that gets a new bike and has to replace a fan and 2 fuses in 3 months ownership and now THIS happens!. The presence of oil in the airbox and the clacking sound when I tried to start it does not bode well at all. the way my luck is running, its probably buggered up both barrels and the head. I reckon I will load it up on the trailer tonight, it will fall off and kill my dog.
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Jonny_fantastic
Posted on Thursday, May 19, 2011 - 10:06 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/231 005_10150177867080509_534885508_7204389_2845494_n. jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/249 170_10150177867370509_534885508_7204391_6913758_n. jpg

the bolt head that I retreived looked well mangled at the end
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Reepicheep
Posted on Thursday, May 19, 2011 - 11:57 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Err, where did you retrieve the bolt from? The muffler?
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Motoqueiro
Posted on Thursday, May 19, 2011 - 12:04 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

was that the one that fell off?
was in a cylinder, or in the manifold?
it's very easy to remove the engine, if it fall in the cylinder, it's also very easy to remove the head and take a look inside, and checked the valves and valve guides
what f**k luck
good luck it's time you start having it
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Jonny_fantastic
Posted on Thursday, May 19, 2011 - 01:41 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

That bit was laying in the airbox when I removed the filter. The other bit of it could be anywhere.
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Motoqueiro
Posted on Friday, May 20, 2011 - 02:28 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

in the air box???
it fell upwards?
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Kalali
Posted on Friday, May 20, 2011 - 03:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I remember reading the same exact thing happen to another member a while back and the piece chewed up the top end on one of the cylinders. Similar thing happened to my X1 but I was very lucky and the throttle shaft broke just like Al mentioned and the screw remained intact in the butterfly. As mentioned before you can't just buy the shaft/butterfly assembly and I ended up replacing the TB as a single unit. In my case the damn thing broke as I was riding and the throttle got stuck open...Fortunately (again) I was just around the corner from my house and I managed to get the bike home without incident.
I attributed my failure mode to a series of backfires I had through the intake due to a poor fuel map while starting the bike. My theory was the backfires through the TB with the butterfly in almost fully closed position put excessive pressure behind the butterfly plate and basically cracked the throttle shaft at its weakest point, where the butterfly is screwed to the shaft, and twisting the throttle finally dislodged the two pieces.
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Froggy
Posted on Friday, May 20, 2011 - 05:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Give this a read
http://www.badweatherbikers.com/buell/messages/142 838/580295.html?1305925710
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