Topic-icon 2005 ZX6R exhaust butterfly valve actuator angle?

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4 years 5 months ago - 4 years 5 months ago #1 by handsomehooligan
handsomehooligan created the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
So I've been having issues with clicking noises from my exhaust butterfly valve actuator (servo motor) and I took it out of the bike to inspect it. It looks fine inside, and upon Googling possible issues, I noticed a lot of issues out there regarding this part and having aftermarket exhaust/FI light problems. This isn't the case for me as I am running stock exhaust. I also noticed that there is a bit of a range of different angles people have the pulley set to when it is in the bike. Can anyone here speak into how to reset this or what angle the pulley should be at? I have included an image for reference. If anyone out there has an 05-06 ZX6R and wouldn't mind speaking in to this or replying with a photo of the angle it is in your bike I would be extremely grateful. Thank you!

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Last Edit: 4 years 5 months ago by handsomehooligan.

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4 years 5 months ago #2 by Ryan
Ryan replied the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
hey hooligan, i messed with that damned thing endlessly to fix the fi light on my 06 racebike. your servo needs to be in the (C) position. if it's clicking and throwing an FI light in that position its likely that the butterfly valve in the exhaust is seizing up and servo isn't able to pull the valve closed.

very common problem on gixxers too with an easy fix to remove the cables and cut the sensor wire out of the ECU, leaving the valve permanently wide open.

Redline Cycle
14-1515 Westgate Rd
250-769-4702
www.redlinemotoparts.com
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4 years 5 months ago #3 by handsomehooligan
handsomehooligan replied the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
Hey Ryan, thanks for the info. I have been doing some reading and that is what a lot of people are recommending. I'm getting the clicking noises when I turn the key on, but I am not getting an FI warning. I pulled on the cables which were a bit tough to pull but not impossible (possible my servo motor doesn't have enough power to move the cables), and I was able to easily turn the spring loaded butterfly valve by hand.

I am noticing that my bike is lacking a lot of power it use to have in the lower ranges especially off the line in the first couple of gears. Maybe a cable adjustment is needed to adjust the tension of the cables as well as how open or closed the valve is.

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4 years 5 months ago - 4 years 5 months ago #4 by Ryan
Ryan replied the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
hey, sorry i'm wrong on the angle of the pulley. i remember it being 40 something degrees off center of the cables... there are also resistance and voltage specs that can be tested to see if it's working properly. if it spun trying to get the bolt on/off and not holding the pulley that could wreck it too. cables should have 1mm play at the pulley. i have the service manual and specs at the shop, just working from memory at the moment.

If the servo is leaving your exhaust closed off then ya you'll be losing power. but that's often fixed with simple spark plugs, valve adjustments, plugged air filters too. get the pulley sorted out first though.

Redline Cycle
14-1515 Westgate Rd
250-769-4702
www.redlinemotoparts.com
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Last Edit: 4 years 5 months ago by Ryan.

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4 years 5 months ago #5 by Ryan
Ryan replied the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
best solution: get a pipe and toss that boat anchor.

Redline Cycle
14-1515 Westgate Rd
250-769-4702
www.redlinemotoparts.com
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4 years 5 months ago #6 by handsomehooligan
handsomehooligan replied the topic: 2005 ZX6R exhaust butterfly valve actuator angle?
I dug up a manual and found the angle in there. I wouldn't mind a new pipe and ditching the servo, but cost and how much I want to invest in the bike at the moment will be the determining factor. I did put new plugs, air filter, and adjusted the valves 2000 km's ago.

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