I been having problems today and cant seem to get the cables in place correctly on the servo. What would really help me is if somebody has a photo or explain how the cables locate on the servo pulley as i just cant get the valve to operate,it either jams the servo being to tight or the cables jump of the pulley to slack.ITS BEEN DOING MY HEAD IN TODAY Also should the valve have tession on it when disconnected like it is spring assisted or loose and free.
Check my thread which has some crude pictures of what you might need. http://www.activeboard.com/forum.spark?aBID=66365&p=3&topicID=30230624
The valve should be free to turn when the pulleys are disconected, they should connect to the servo (motor unit) like this:
Turn ignition on, servo motor unit does turn cycle left/right then sits with the holes for the cables at about a 9 o'clock position. The shorter cable then attatches to the hole that is towards the bottom, goes straight down, through the hole in the plastic servo case, through the rubber cover and then into the left side of the powervalve cover on the engine.
At this point you should make sure that the valve is alligned in the correct position to the hole, double check by looking up the exhaust and checking it is flush with the roof of the exhaust port.
Screw it all the way in and attatch the pulley to the left side of the valve slider.
Repeat with the right side cable, it runs over the top of the servo (motor unit) pulley, so it comes from under, and goes over the pulley from the right hand side to the left.
Once both cables are attatched, tighten the pulley cables by screwing them out of the metal housing on the engine, once they are tight loosen them a turn each and check that they turn freely by turning the ignition on and off.
Here is a picture of the basic cable routing, i am presuming your bike is a newer model that doesn't cross the cables over.
-- Edited by Soleconsumer on Monday 14th of September 2009 06:54:54 PM
Also. If when the pulleys are detatched from the powervalve it doesn't turn freely you will need to strip the valve unit and clean it out. I did this myself a few weeks ago
Thanks for you help, I cant open the link you posted. Ive ahad a go tonight and i can get the valve moving both ways using the servo but when it settles it is not lining up with the V and hole on the housing.Can the valve be moved round on the bracket where the cables attach by undoing the 10mm bolt??
when i do this it puts to much pressure on the servo and stops it working correctly,im thinking can it be adjusted on the end of the valve by undoing the 10mm bolt and moving the valve slightly round without moving the cables.
Had another fiddle with the valve servo again tonight. I just cant seem to get the hole and the v lined up.I can get it slightly to the left of the hole with 1 wound right out and 2 wound right in any further and it all jams up with the cables being to tight. Is there a chance something has slipped out of sinc. Solecomsumer mentioned that the cable slots on the servo pulley should be at about 9oclock mine are at about 7. Any ideas or suggestions??
its a 2005, i cut a bit of the black outer cable back to take a bit of the tension out of it.Im baffled as to why i have to this something has got to of moved. If i have to leave it slightly off centre am i better to the left or to the right of the hole??
Thanks for the attachment, Ive tried to blow it up but it gets to blurred. All i need to see is the arrangement of the cables around the motor pulley,im currently looking for a manual,im going to have another fiddle when i build the head back up one day this week. Thanks again for your help mate. Carl
