| Author | Message | ||
     Tootal |
For those of you that have had the unfortunate and dreaded TB shaft breakage and are contemplating replacing it yourself I thought I'd make up a pictorial that might help. First off, go get a manual for removing and disassembling the throttle body. Give it a good cleaning and come back and meet me here! So let's start off with one naked throttle body. (Thanks Maximum)  Remove the teflon split bushings and inspect them. I hope they're good!  Now reinstall them. Take the e-clip and tps pin from the broken shaft and install in the new one. You can use a vise and a pin punch to get it out. I put a small nut against the vise and the shaft and pushed the pin into the nut with the vise, then finished it with the pin punch. Now install both of these onto the new shaft.  Start the shaft into the tps sensor side and slide though the throttle body. Be sure you don't push the bushing out the other side.  Now install the actuator and nut and snug the nut down.  Now install the butterfly. It needs to go exactly how it came out. Make sure the numbers are parallel to the shaft. At this point you can insert the screws but don't tighten them yet.  There should be some play length wise in the shaft. Push the shaft toward the actuator's side and take a feeler gauge and measure the total gap size.  Once you know the gap size, divide by two and use that size feeler gauge to set the shaft. I apologize for the blurry picture, it's hard enough to press the shaft hard enough to hold the feeler gauge in place while also holding the butterfly closed! Now snug the screws down evenly.  Now open the butterfly a little and make sure you have some side to side play. It should be free. Now open enough to get your allen wrench in there and just tweek them a little tighter. I would use red loctite or equivalent on these screws.  At this point I would rotate the shaft around so you can see the bottom of the screws. If you can get some sort of a rod up through the discharge holes to back up the shaft then take a center punch and flare the bottom of the screws to help insure they can't back out. This is the hardest part of the assembly but will give you some peace of mind in the long run. Now you can remove the actuator and install the spring and everything else. Assembly is the reverse of disassembly! When installing the tps sensor, hold the butterfly closed and while the tps sensor is still loose, rotate it till you feel contact with the tps pin in the shaft then rotate it about 1/16" more. This will put spring pressure against the pin at all times and will help with a steady idle. (Thanks Treadmarks!) If you have any questions please PM me and I will get you the info you need. | ||
| Tootal |
I just realized you can't rotate the butterfly around unless you take the actuator off the shaft. So needless to say, once the screws are tight remove the actuator and then rotate the shaft around to the screw bottoms. | ||
| Paul56 |
Thank you, Greg. PM sent | ||
| Tootal |
Well it finally cooled off around here and my garage isn't over 100 degrees! If you have a piece of shafting around 1/2" to 5/8" you can mount it in a vise:  Place the TB onto the shafting:  Now line up the shaft with the head of the screw to be center punched:  Rotate the butterfly and feel the screw head with the shaft and hold it there. Take your centerpunch and center it with the screw tip:  Now smack it with a hammer!! My favorite part! That should keep it from coming out! | ||
| Kyleh |
Quick question for folks who have done this - Did you find a TPS reset was required? I've installed this piece (quality!) and I find the bike runs very well at low throttle/cruising speed. However, when you jump on it, the bike falls on it's face and doesn't really accelerate. Makes me think it's a TPS-related issue. I'm thinking my only recourse is the dealer if I don't have my own tuning software and interface cable. I'd like to know if I'm on the right path here, or if it's something else I've not done quite right.... | ||
| Tootal |
Yes, tps reset is required. | ||
| Maximum |
Finally got around to installing my new shaft...beautiful job Greg! | ||
| Tootal |
Thank you sir. Glad it worked out.  | ||
| Sweetfish89 |
I know this is an old thread but I was wondering where yall got your shafts from? And a part number would be great? | ||
| Melovebuell |
Hi Tootal. pm sent. your mail not playing along | ||
| Ruans187 |
HI, Is the Trottle body shaft some that I change when it brakes or at what mileage? thanks | ||
| Tootal |
Juan, I've sold 79 shafts so far but considering how many bikes are out there that didn't break your odds are pretty good. Here's what I recommend. If you're traveling a lot in lonely places then you might want to consider getting a shaft just for piece of mind. If you just ride locally then I'd take my chances and if it breaks then by all means let me know and I'll get a shaft to you. So think about it and let me know what you would like to do. I know some of the guys on the BadWeb will tell you that you need it because they had one break and it stranded them but like I said, many more have not broken. | ||
| Dualsportdad |
Thanks Tootal for the shaft, my Uly is back up and running! | ||
| Maximum |
Good to see this thread still active. Brings back some memories!!!  | ||
| Froggy |
Maximum, good to see you are still around  | ||
| Court |
>>>Maximum, good to see you are still around You can say that again . . . >>>Maximum, good to see you are still around | ||
| Maximum |
Thanks guys. Sorry to hijack this thread Greg. I still have my two Uly's and 1125r...but have not been riding much. Had a "minor" encounter with a chainsaw to the knee cap last summer. I'm back to 95%...but life has me going in other directions. You can see my current addiction on YouTube...HERE I do miss everyone...many great memories here and at the many gathering I've attended. | ||
| Tootal |
Ha! No need to be sorry Maximum, this thread and project was all because of you! Sorry to hear about your accident but I understand. I shattered my heal two years ago while hiking. I should have stayed on the bike! Fortunately it hasn't kept me from riding. Running maybe, but not riding. Glad to hear you're doing well and I think Court might be liking your new hobby! Good luck with your new endeavor! |
