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Installed New Exhaust, Moved Butterfly Valve Actuator - Now Warning Lights ('07 ZX6R)

JohnnyBlaze

JohnnyBlaze

New member
Joined
Sep 18, 2003
Location
Santa Rosa, CA
Moto(s)
2001 Kawasaki EXTwoFiddy (WRITE ME A TICKET RED)
I just installed a new Two Brothers after market exhaust on my bike. 2007 ZX6R

When I removed the servo cables from the Butterfly Valve Actuator...I know I moved the pulley a few times on accident. I may have damaged it and I am almost positive it is surely out of place (I did not remove the actuator itself, only the cables...but I had to take the actuator off to get the cables out). I did put the actuator back on in the best orientation I could but since I know nothing about it I am sure it may be wrong.

Now, the bike is reading an "FI error" (Fuel Injection)...But the error code is 63 which is "Exhaust butterfly valve actuator malfunction, wiring open or short" from what the service manual tells me.

The service manual further says this about code 63.

"If the exhaust butterfly valve actuator fails (the
signal is out to the usable range, wiring short
or open), the ECU stops the current to the
actuator."

__________________________________________________

So my question is this...

I am not utilizing the butterfly valve actuator with the new exhaust any longer. But Since I may have damaged it...would I need to buy a completely new one? ($209). I was thinking maybe some of you techies can tell me a way to clear the code so I don't have to worry about it anymore. I have already tried disconnecting the battery for several hours to reset the system but that did not work. It really sucks that I might have to buy a new actuator since I am not even using it in the first place. My concern is that I need to get that error code cleared so that any further problems down the road will show up correctly. I can't just keep riding it with this error code going off...

Any advice would be greatly appreciated.
 
What is the usable range in the service manual? Tried putting a meter on it and doing the test?
 
Actuator Output Voltage (Pulley Original Position)
Standard: 3.46 ∼ 3.76 V

Don't have a meter though, to do the test!
 
Meters are $10 for cheap, mildly accurate ones. Decent can be had for under $60 and pretty damn nice for $150.

I would strongly suggest you acquire one -- it's going to save you a lot of hassles.

Anyway, assuming it's okay, but just out of position, you could use a meter to get it roughly back in the right place, and that could solve your problem.
 
I wonder if there is anyone in the East Bay or Modesto area that can look into this for me for a small price!

I'll definitely check into buying a meter in the meantime...learning how to use it correctly is the next step!
 
That's a common alarm when the butterflies are disconnected. There is a simply fix for it (can't remember the specifics) .... do a search on the kawaski forums.
 
doesn't the new exhaust come with a little "stop" that bolts on to the servo motor so that when you start the bike & the servo pulley rotates the "stop" limits its travel, fooling the computer into thinking the servo is still hooked up & everything is fine?? it should.
 
elskipador said:
doesn't the new exhaust come with a little "stop" that bolts on to the servo motor so that when you start the bike & the servo pulley rotates the "stop" limits its travel, fooling the computer into thinking the servo is still hooked up & everything is fine?? it should.
Click to expand...

Unfortunately there was no such part in my after market kit from Two Brothers. I called Two Brothers to see what they thought...and they told me I need a power commander or I need to reset the system by disconnecting the battery. They also said that I may have moved the actuator or damaged it and may need a new one. But I am thinking if there is no resistance because of the servo cables being abscent than whats the point of getting a new butterfly actuator motor since A) I am not using it, and B) cables are not going to be hooked up to it anymore so it may know there is no resistance.

I disconnected the battery and that didn't work. I do want to get a power commander in the future but I still don't see how that will fix my direct problem.
 
MY roomate has the 636 and took off the actuator cables and wired the butterfly all the way open and then cut the little wire going into the ecu and no more fi light . I did the same thing on my gixxer :thumbup
 
Problem solving tool? :twofinger

Just cut the red wire, or was it the blue wire...

cutter.jpg
 
I'd strongly suggest finding a way to jumper the end via an appropriate value resistor, if that's what it's looking for, or some sort of stopper.

If you must cut, cut close to it, and not further up the harness; make things easy on the next owner if you ever sell that bike.
 
Thanks everyong for the advice (although some was bad, some good) :rofl

I have finally figured out a few ways to fix this that keeps the ECU monitor working correctly in case of other warnings.

A) you can purchase "Ivan's Servo Eliminator" for around $100 and that will completely replace the servo motor eliminating the FI warning light but keeping every other function in tact.

B) You can take the servo motor apart and check to see if you broke off any of the teeth of the plastic gear inside that rotates the pulley. If you broke any teeth (which is what I did, hence the warning light malfuntion) then you can take the gear off, rotate it 180 degrees, and put it all back together.

C) You can buy a new servo motor either new or used in good condition and replace the damaged servo motor.

There is no need to try and "TRICK" the system....as long as ther servo motor has the correct output voltage and the teeth of the inside gears are not broken (from moving the servo wheel without holding it with pliers like your suppose to) than the computer will think it is working properly...the key is that it is in the correct position and moving clockwise, counter clockwiese, then clockwise again at startup. The servo motor does not need a "stop" or "Pseudo Cables" to make it work correctly...it just has to be on there able to move the way it normally would. The test from the ECU is not based on resistance or friction...it is based on voltage output and rotation.

Hope this helps anyone else with this problem.
 
:thumbup Excellent news!

Pick up that meter anyway, if you're going to wrench -- it'll come in handy.
 
JohnnyNorCal said:
The servo motor does not need a "stop" or "Pseudo Cables" to make it work correctly...it just has to be on there able to move the way it normally would.
Click to expand...
you may want to rethink this statement...... several exhaust companies supply "stops" that bolt to the servo so that the voltage/resistance/etc... all remain the same as when the stock system was hooked up, & this is essentially fooling the computer that everything is normal & proper. & there are ways to trick the system. on a lot of gsxr's removing a certain plug/pin from the ecu connection will elminate the fi light that comes on when the cables or servo is unplugged. for the last generation zx6 two bros sales part #005-125-05-01 that fixes the FI light. its a "stop" for the servo motors rotation.
 
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