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CrazyMotorcycleGuy
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Unusual clicking from throttle bodies when bike primes?!?!
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Unusual clicking from throttle bodies when bike primes?!?! - December 27, 2009, 08:48 PM

So I put a new (used) engine in my winter project (2007 ZX6-R) and fired it up on Friday for the first time

But I have a concern/question, the bike runs strong, sounds good, all cylinders are firing, but I noticed that when I turned the bike to the "on" position and the fuel system primes, the throttle body valves open and close (like most newer bikes do, the valves open and close right before you hit the starter) but when the valves go to the full open position, they seem to want to keep going, they hit the max open and it will click 3 or 4 times as if it wants to open even more, and then they will return to the normal position before i fire it up, what do you think this is? You think this is a problem? Any Kawi owners hear this before?

Other than that, everything seems to run perfect and sounds great, thanks for the help


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December 27, 2009, 10:00 PM

Call RNR they are Kawi experts, but our closed tomorrow.
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December 27, 2009, 11:03 PM

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Call RNR they are Kawi experts, but our closed tomorrow.

they are closed till after the new year....so prolly the 2nd...



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December 27, 2009, 11:13 PM

Send a PM to Widow Maker because he recently bought the exact same bike. Ask him what his sounds like. If it's abnormal, I guess the first thing I would do is pull the tank and air box to see whether something is misaligned and interfering with some linkage around the throttle bodies. Sometimes people throw a bike back together in a rush and are not careful about properly routing vent hoses and fuel lines. Putting an air box and tank back down sloppily can have consequences.


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December 28, 2009, 07:07 AM

Quote:
Originally Posted by OrangeShirtDude View Post
Send a PM to Widow Maker because he recently bought the exact same bike. Ask him what his sounds like. If it's abnormal, I guess the first thing I would do is pull the tank and air box to see whether something is misaligned and interfering with some linkage around the throttle bodies. Sometimes people throw a bike back together in a rush and are not careful about properly routing vent hoses and fuel lines. Putting an air box and tank back down sloppily can have consequences.
I was pretty cautious putting it all back together, but maybe I'll go back in and check everything again, I'll PM widowmaker right now, thanks!!


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December 28, 2009, 07:55 AM

PM sent


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December 28, 2009, 11:40 AM

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PM sent
thanks, sent one back your way!


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December 28, 2009, 02:13 PM

If you pull the tank and air box off, run the prime sequence a few times and see if you can see anything unusual going on there.


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December 28, 2009, 05:30 PM

Quote:
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If you pull the tank and air box off, run the prime sequence a few times and see if you can see anything unusual going on there.
yeah, i tried that, but no cigar

I mean it all looks normal, except that on the upward motion of the valves, they just tend to click 3 or 4 times in full open, then return to normal, the bike ran perfect when I did a flush on it (20 minutes, revving to different engine speeds), and then again with fresh new fluids (15 minutes)

what do you think?


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December 28, 2009, 10:19 PM

here is a video of the valves

http://www.youtube.com/watch?v=jJvtJG1nUZw


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December 28, 2009, 11:12 PM

Sounds like the actuator is stripped out.

Did you take it off the throttle bodies ever?
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December 29, 2009, 07:30 AM

Quote:
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Sounds like the actuator is stripped out.

Did you take it off the throttle bodies ever?
over on the Kawasaki forums they are saying its normal?

But to answer your question, no the entire throttle assembly was attached to the new (used) engine when I installed it, the only thing I took off was the airbox, then reinstalled it when I got it all hooked up, this is a video of the bike running, with no apparent problems, and after I had it warmed up I got the RPM's way up there, with no strange happenings...

http://www.youtube.com/user/SpykerFi.../1/itHsaDqVGq4


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December 29, 2009, 07:36 AM

lol at kawi

jus take it out and run it - what's the worse that can happen? If it doesn't do it when the throttle is open or while riding - what's the problem?
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December 29, 2009, 07:39 AM

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December 29, 2009, 11:26 AM

I haven't owned or worked on that bike, but on my 10r, the secondary butterflies (what you're calling "valves") are fully closed when everything is off. I'm willing to bet that the actuator on your bike is jacked since the butterflies are not closing all the way. What's happening is since the carrier shaft is already partially turned, the shaft cog is hitting a stop before the actuator is finished doing its business. If you can reset the shaft so that it's in a position for the butterflies to be closed completely, you'll eliminate the chatter.

If you decide to remove the secondaries while you're in there, be informed that the screws are held with red locktite and are a beyotch to get loose w/o stripping the heads. You need to experiment with different sized-screwdrivers and make sure they are fresh. You'll need some ki energy and complete concentration too. Oh and a retrieving magnet can come in handy too.


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