Ehaust Butterfly Valve

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Ehaust Butterfly Valve

This is a discussion on Ehaust Butterfly Valve within the Z1K/Z750 Maintenance forums, part of the Kawasaki Z1000, Ninja 1000, Z800, Z750 & Z-750S category; Hello fellow ZED owners. I seem to be having an issue with my fuel injection warning light. I am getting an error code of 63 ...

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  1. #1
    Up-And Comer logspec12's Avatar
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    Unhappy Ehaust Butterfly Valve

    Hello fellow ZED owners. I seem to be having an issue with my fuel injection warning light. I am getting an error code of 63 which tells me it's the exhaust butterfly valve. When I took the side cover off the valve doesn't look anything like the one in the service manual. Has anyone ever come across one that looks different? I don't want to continue riding it if it might do some damage. Any ideas? I'm will be attaching some pictures so you can see what I'm refering to.

  2. #2
    Up-And Comer logspec12's Avatar
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    Here are the pictures I was taking about. I'm really confused as to why it looks so different.

  3. #3
    Site Elder jsmith8008's Avatar
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    You do seem right. This is from the second gen manual. What years your bike?

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  5. #4
    Site Elder fast_stakes's Avatar
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    I'm assuming you bought the bike pre-owned and it has an after market exhaust on there. That plate looks like a plate that was installed to fool the computer into thinking the servo cables were still hooked up. The points on either side would contact the servo motor housing making the computer think the valve in the exhaust is fully open or closed without having the valve there.
    Sometimes it takes a whole tankful of fuel before you can think straight.

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  6. #5
    Up-And Comer logspec12's Avatar
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    It's a 2007. I bought it used with a Scorpion exhaust already installed. Will having this problem effect anything major or can I still ride it?

  7. #6
    Site Elder fast_stakes's Avatar
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    No, it will not affect anything major. Without the butterfly in the exhaust, all it will do is give you an annoying light on the dash.
    Sometimes it takes a whole tankful of fuel before you can think straight.

    “Insisting on perfect safety is for people who don’t have the balls to live in the real world.”
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  8. #7
    Site Elder schap's Avatar
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    Interesting. Because it's a 2007, I don't think you need that plate to fool the ECU...it doesn't care (at least mine doesn't). Can you remove the plate? Be careful not to turn the motor while removing the bolt.

    Let me get some video of mine to share.
    Schap! (or "Schlap" to some)
    2007 Kawasaki Z1000 w/ Full Race 4-2-1 Akra, PCIII, K&N, Airbox Mod, Engine Ice, Pro Taper Evo RM Low, Bar End Mirrors, Evotech Tail Tidy

  9. #8
    Site Elder schap's Avatar
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    Sorry for the crappy lighting in the video. Hopefully, you can still see that the servo motor does not need to touch/bump anything to trick the ECU when starting the bike.

    http://www.youtube.com/watch?v=GcvkDa42tfo

    I wonder if your plate is actually stuck or hitting one of the sides, which tells the ECU that the motor is stuck.
    Schap! (or "Schlap" to some)
    2007 Kawasaki Z1000 w/ Full Race 4-2-1 Akra, PCIII, K&N, Airbox Mod, Engine Ice, Pro Taper Evo RM Low, Bar End Mirrors, Evotech Tail Tidy

  10. #9
    Supreme Being Azweepay's Avatar
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    Good point Schap. There seem to be some scratch marks by the right side tip. Is it making contact and dragging?

  11. #10
    Site Elder schap's Avatar
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    Quote Originally Posted by Azweepay View Post
    Good point Schap. There seem to be some scratch marks by the right side tip. Is it making contact and dragging?
    I hadn't noticed the scratches. The tip looks like it could be bent.
    Schap! (or "Schlap" to some)
    2007 Kawasaki Z1000 w/ Full Race 4-2-1 Akra, PCIII, K&N, Airbox Mod, Engine Ice, Pro Taper Evo RM Low, Bar End Mirrors, Evotech Tail Tidy

  12. #11
    Up-And Comer logspec12's Avatar
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    The tip isn't bent, it looks like it was made that way. I haven't tried to run it without the plate installed. I'll try it when I get home from work. I just found it strange that it only recently became a problem. I was unaware that there was a plate there. I have black electrical tape over the light so I can't be annoyed by it anymore. I think I might need a new servo motor though. Maybe it just quit working. I did notice when I pulled the plate off and removed some of the rust and put it back on the light went out at first, then came back on. The motor did rotate the plate and seemed to work at first and then it just stopped in the position it was in. I hope I don't need a new motor. That'll be about $185.00.

  13. #12
    Site Elder schap's Avatar
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    Quote Originally Posted by logspec12 View Post
    ...The motor did rotate the plate and seemed to work at first and then it just stopped in the position it was in. I hope I don't need a new motor. That'll be about $185.00.
    So, the motor/plate doesn't turn when you first turn the key to the on position?

    If so, then the motor itself may be shot or just need some adjustment/maintenance. The plate itself looks rusty. Have you exposed the motor to much water (rain? washing?)? (Thinking how to avoid this in the future if you have to get a new motor...)

    EDIT: The servo motor eliminator would be cheaper at $110 than buying a new motor: http://www.ivansperformanceproducts.com/other.htm
    Last edited by schap; 06-09-10 at 10:06 AM. Reason: Link to servo motor eliminator
    Schap! (or "Schlap" to some)
    2007 Kawasaki Z1000 w/ Full Race 4-2-1 Akra, PCIII, K&N, Airbox Mod, Engine Ice, Pro Taper Evo RM Low, Bar End Mirrors, Evotech Tail Tidy

  14. #13
    Newbie MaxWedge's Avatar
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    Yeah that pully looks like it's scratching the surface behind it, and it's definately not the stock piece. Take it off (the rusty pully) and see if it fixes it. If not get the Ivan's piece listed above, or if you can find one cheap, a used servo motor.

  15. #14
    Up-And Comer logspec12's Avatar
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    Schap,
    I removed the pulley and the FI light still stayed on. The motor shaft seems to have about an eighth inch play in it so when I pulled on it a little the motor started to work again and the light went out. Very strange.

  16. #15
    Supreme Being Black Sheep's Avatar
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    I got the FI warning light once after removing the cables. But I just rotated the pulley a few degrees and then turned the key on again. It seemed to be happy once I "aligned" it in a way it would accept and stopped throwing the error. Not sure if that is your issue, but it's free to try!


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