wire cylinder assembly

[msmith1512]

Hi Guy & girls.
I have stripped my TZR250 2MA and am now rebuilding it.
I cant remember which cables connect to which point inside the wire cylinder assembly.
The placy box that connect the throttle cable / oil pump / servo.
Have done loads of photos to help me remember how it goes back together, but sods law got none of these.
Have got a manual but it does not show this.which i find a bit odd as this is probably important info for a rebuild.
Can any one help?
Matt

[oldbiker]

I know it`s a bad picture but I hope it helps, What`s your location??

[mickey]

This is looking at it from above the Header tank.Top of pic is where oil pump cable comes in(can just see it),the servo disc has two levels(Grooves) the pump cable solts onto bottom one and PV cables onto top one.The PV housing and servo motor have 1 and 2 written on them so you run cables 1 from PV housing to 1 in servo motor and same with 2.

[tzr_andy]

Thats very interesting as my spool appears to be 180 degrees out (assuming you took the pic with the PVs in their starting position).
I've been having loads of problems getting my PVs to set correctly so they don't project into the exhaust port when the ignition is off (i.e. the fully open position).
Will disconnect my cables, rotate the spool through 180 degrees and reset cables to see if that makes a difference.  Is anyone aware of the servo's resetting in other positions?

[Martin77]

I seem to recall it's possible to remove the pulley from the shaft, so maybe try putting it back on facing the other way?

[tzr_andy]

The pulley does come off although mine is seized solid.
I won't be doing that though as that's not how Yamaha intended it, so there must be some other fix.  I'll be doing the rotation by hand next time I'm in the garage and checking to see what the result is.
Annoying it most definitely is, as my next job is to reduce the squish clearance down to around 0.5 mm, but that'll be a bit pointless with the PV restricting the exhaust port.  Hurrumph!

[Fotis]

you can trick the controller to turn it around by supplying it with fake input data from the servo sensor. Maybe you used different plugs on the servo side or someone re attached the wires in the plug wrong. Make sure that the servo wires attach to similar controller color codes.  (red to red, black - black etc)

[tzr_andy]

Did some more digging about and think I've sorted it (again).
Full story here - http://andywheeler.net/YPVSissues.aspx