Finished removing the secondary flies shaft and Servo. pic. heavy - Kawasaki ZX-10R.net
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post #1 of 20 Old 01-15-2010, 08:21 AM Thread Starter
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Finished removing the secondary flies shaft and Servo. pic. heavy

I just finshed up modifying my throttle bodies (08 ZX10).

Pulled off and ready to remove the Secondary flies shaft and servo motor.
I bought some wire label stickers to keep track of what goes where and to be certain I connect them "all" the first time.



Before I split them apart I took a quick measurement to keep 1&2 / 3&4 in sync.



Split with shaft and servo removed.



J B Weld setting up. I did buy some quick dry (4 minute setup time) J B Weld, but decided for this application to use the original. It took alot longer to setup, but worth it.



I let it set overnight and used a pencil grinder to smooth down the high spots.



I just had to get rid of the lip right above the primary flies. Its bigger than it looks.



A combination of fine grit sandpaper, scotch brite, and WD-40 smoothed things up nicely.



Much better than before!





A little tip on double checking the sync. I use a thin piece of shim stock
(.010" in this case) the make sure the gaps are the same. Even though I measured between the spring and screw, mine were still just a bit out of sync.



I'm going to give bypassing the servo and subthrottle sensor a shot when I reassemble. If not, the exhaust servo is going in the garbage.

Now I just need to decide if I want to tear into the topend while I'm half way there.
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post #2 of 20 Old 01-15-2010, 09:37 AM
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Nice rite up!! REP SENT>>
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post #3 of 20 Old 01-15-2010, 09:42 AM
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Good post
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post #4 of 20 Old 01-15-2010, 09:52 AM
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Nicely done, let us know what you think about how it runs
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post #5 of 20 Old 01-15-2010, 09:53 AM
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nice man, hopefully the 08's dont go into limp mode :-p
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post #6 of 20 Old 01-15-2010, 10:08 AM
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I was thinking that there might be a way to lessen the secondary flies' restriction without major work and without the ecu complications of a dead servo circuit. Here goes....how about removing the secondary butterflies and cutting off the upstream half of the plate (leaving the mounting holes in tact) and then re-installing them. This way you have opened up at least 1/2 of the 2nd flies restriction and have allowed the servo to remain connected to the ecu. It may have the potential to give you a good compromise. Had a buddy do this on a '08 turbo busa install and it seemed to work well.
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post #7 of 20 Old 01-15-2010, 10:51 AM
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Very nice write up doing this on my 636 as we speak.
Hoping to get away with not using the servo motor as well....But pretty sure the 636 goes into limp home mode damn it...
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post #8 of 20 Old 01-15-2010, 10:59 AM
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I think for the most part when the bike gets sent into a limp mode is just the secondarys being stuck shut so that will make the bike "limp"

easy way to find out with out going threw everything is pull the secondarys and just unplug the servo motor and ride it. If all is good yank that shit off :-)
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post #9 of 20 Old 01-15-2010, 11:22 AM
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does this not do the same as just removing the secondary's? what is the benefit over just taking them off?
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post #10 of 20 Old 01-15-2010, 11:25 AM
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will eliminate any other unwanted interuptiopn of air flow going into the motor as well as weight savings....
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