Top butterfly mod. - ZX6R Forum
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post #1 of 12 Old 04-20-2009, 08:32 PM Thread Starter
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Top butterfly mod.

Ok, seems to be a lot of buzz about the top butterfly removal on here of late & since it'll be a few months until my ZX is back on the road I figured I'd get off my ass & do somethin' with the girl.

One thing I'm not sure of is how serious individuals are getting with this mod.... I'm one to think that if you're going to do somethin' then by god DO it! What I'm refering to is whether or not people are removing the entire butterfly assembly or just taking the plates off the rod.

I couldn't sleep last night as usual so I grabbed a beer & pulled the ZX into the dining room. I dove into the project intent on removing anything north of the injectors, I've ridden with my FI light on for 10K already cause of my exhaust so I figure if yankin' out this stuff trips a sender who cares right? I plan on having just a mini tach soon with my new headlight bracket I'm dreaming up so all those idiot lights will be gone anyways. I took a few pics along the way so that this might help somebody down the road.

First off, my tank, seat etc. was already off so that's where this takes off at. Besides, I figure if you can't get to that point without help you might not want to be goin' this deep in the bike. Oh yeah, this would pertain to an 05 or 06 6R

Take the air box off.



By the way, what are these two little black boxes? One has a nipple out the bottom & the other has a vacuum line going to the throttle bodies. I assume this has somethin' to do with atmospheric pressure versus intake pressure for the injection system I'm just guessing here.



Remove the injector loom, vacuum lines going to the cracnkcase breather (kleanair, if you still have one, I do, just 'slightly modded') along with the fuel line & butterfly motor wiring. I didn't take the throttle position sensor wiring or throttle cables off yet, as they are a serious pain in the ass & would be much easier to access later.



There's two tiny little allen head bolts in between the number 1 & 2 throttle bodies & likewise for number 3 & 4 facing towards the front of the bike as you're standing over it. These are a pain but do-able.



Pull the throttle bodies out of the rubber intake boots.



PUT RAGS IN THESE HOLES! Make sure nothing falls in your beloved motor!



Remove the throttle cables & throttle position sensor wiring & you get this.



Remove the butterfly plates with a phillips screwdriver.



This is as far as I made it last night, took me about half an hour & I've never done this before so it's rather easy. Tonight I plan on getting the rod out & trying to figure a way to seperate the throttle bodies without eff'ing up my sync. Then I'm going to tap the holes that were previously occupied by the butterfly shaft & fill them with allen headed plugs. Finally I'll probably JB weld over them & very finely sand them smooooooooth. Hopefully, when I'm done, it'll look like the bike never came with the buggers. I'll progress again come tomorrow, ya'll have a good one!

-Cessna three zero november

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post #2 of 12 Old 04-20-2009, 10:22 PM
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im in the same place right now. my bike is apart, i cant sleep and idk what i can do to it. i was changing my plugs and air filter and i broke one of my iridium plugs gaping it and no one was open to get another. plus cycle gear didnt have my air filter. does this really make a gain in power? it looks like its an automatic choke for when its cold. so idk if i wanna take it out since it gets pretty cold out here during winter. whats the call?

oh, really? thats whats up.
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post #3 of 12 Old 04-20-2009, 11:04 PM
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if your going to be a pig go the hole hog. dam thats full on i only took off the flys good luck with it man

It's better to burn out than fadeaway.....
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post #4 of 12 Old 04-21-2009, 10:05 AM
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im not sure i fully understand what is going on here and what do you gain from this im assuming that if you are doing it then it must be a worthwhile mod. can somebody fill me in on my stupidity...lol

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post #5 of 12 Old 04-21-2009, 02:13 PM
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Quote:
Originally Posted by shag View Post
im not sure i fully understand what is going on here and what do you gain from this im assuming that if you are doing it then it must be a worthwhile mod. can somebody fill me in on my stupidity...lol
right then Stupid, what is happening here is one step further than just removing the top butterfly valves. when you remove the top butterfly you still have the shaft left in the throttle body. this is removing the shaft and filling in the holes.


no offence meant by the way
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post #6 of 12 Old 04-21-2009, 05:24 PM Thread Starter
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I thought that when people were mentioning this mod they were just taking the plates off. I figure if just that makes a difference, going through the trouble of removing the rod should do something worthwhile.

I'm nowhere near a dyno shop (middle of BFE Kansas) so what I was thinking is before anyone follows my lead, I would eat the shipping to send these once I'm done to someone & then they could dyno run them versus stock TBs. Everything comes down to real world numbers so then we would all know what it's really worth to do this.

Any takers??

I didn't get to tapping the holes last night as I couldn't find a suitable tap. I'll be leaving out to location 6am sharp tomorrow for work so even though I might be able to get on a public access computer while stuck in a motel at night, I won't be able to update this until I have overcome these two hurtles.

If anybody has ideas as to how I might go about this a better way let your voice be heard! I'm shoot'n from the hip here peeps. Here's a bit of progress I made last night.

Remove this small screw under the butterfly position sensor. It's a T-25 if I remember correctly.



Gently pry the control box off the shaft. This takes a little finesse.



There's a little white plastic e-clip around the shaft locking it in place.



There's a small rubber hose in between the two TB assemblies. Cut this horiziontally.



Then there's a small metal e-clip against the right TB assembly, a small screwdriver & patience will remove it from around the shaft.



File the rough spots on the shaft where the screws went through as these spots won't allow the shaft to pull out the TB holes.



As you slide the shaft out, try to catch as many little springs, washers & spacers as you can. Something went flying across my dining room, I hope I don't need it later!

Here you can see I used the highly scientific 't-shirt on lap' recovery method!



Now this is how throttle bodies should look as God intended.... No crap above the blades!



There's three 8mm bolts that connect the two Tb assemblies together. I thought I was going to have to remove the number two injector there's just enough space for it to unscrew. It won't come out so you can't loose it either! Also, take the vacuum hoses apart inbetween number two & three here.



As you easily pull the two assemblies apart get your third hand out & catch these two springs. In an attempt to not disrupt the sync, I didn't touch any adjustment screws.



Then you have this.



I re-assembled the assemblies a couple times double checking the sync. They still all snap close in one nice, sharp, loud click!

That's all the farther I made it last night, catch ya'll on the flip side!

-Cessna three zero november

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post #7 of 12 Old 04-21-2009, 06:37 PM
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Originally Posted by rattyzx6 View Post
right then Stupid, what is happening here is one step further than just removing the top butterfly valves. when you remove the top butterfly you still have the shaft left in the throttle body. this is removing the shaft and filling in the holes.


no offence meant by the way
how does not having the valves benefit? I said stupidity for a reason. lol I only know (mechanically) about things I have already done. everything i know is from experience. lmfao!
Remaker likes this.

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post #8 of 12 Old 04-24-2009, 03:34 PM Thread Starter
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how does not having the valves benefit? I said stupidity for a reason. lol I only know (mechanically) about things I have already done. everything i know is from experience. lmfao!
It helps smooth out / un-restrict the airflow into the head.

I just got back from location so I'm gonna get crack'n on this project some more this weekend when I have time. Stay tuned ya'll!

-Cessna three zero november

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post #9 of 12 Old 04-28-2009, 06:04 PM Thread Starter
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Ok, so obviously I didn't make any progress on this project last weekend, probably due to a last minute trip to a long lost friend's wedding reception or an all night beer pong tourny, but...

Today having no cash for the vending machine to digest I opted to use my lunch half hour to do a little work. Besides, my rig at work has a helluva lot more tools than my house does!

First off, once the TB's are seperrated, there's two little roller bearings to remove. One is on the end by where the actuator motor for all this B.S. used to be & the other one is on the inside of the 1-2 TB.

A very small screw driver, a light hammer & patience is needed here. You sure wouldn't want to put a big ass nick on the inside of your TB's would you? So just be calm here & trust me, they'll come, they always do.



Then you have a larger hole. (Left one.)



Wanting to have plenty of meat for the allen plug to bite into, I drilled out the outer holes where the rod went through. Also, you'd have to do this anyways to get the tap for the inner holes TO the inner holes. There's going to be three sizes of holes for this. Come to find out the very inside four holes tap nicely with 1/4 inch, I used a fine thread.

The next size larger holes I drilled out with the closest fitting bit I could find, which was an 11/32. This will be tapped with a fine thread 3/8th inch. The largest holes, which is where the roller bearings came out I drilled with a 15/32 & it will be tapped with a fine 1/2 inch.



Finally heres a shot showing one of the inner holes threaded & ready to get plugged.



Also, do all drilling & tapping with the TB's upside down to prevent aluminumm shavings from goin' anywhere they shouldn't!

Ya'll have a good evening & thanks for tuning in!

-Cessna three zero november

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post #10 of 12 Old 05-19-2009, 07:50 PM Thread Starter
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Starting to put the plugs in the holes.



A little dab of JB weld & smooth it out.



& then you have a clean shot to the blades (left one) like God intended throttle bodies to be!



I think I'm gonna smooth out the spots of JB weld with micro fine sandpaper before re-assembly.

-Cessna three zero november

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post #11 of 12 Old 05-19-2009, 08:11 PM
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Would this work on an 04 also? I mean the butterfly removal?
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post #12 of 12 Old 05-19-2009, 08:16 PM
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yes u can do this to an 03/04 as well


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