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Servo motor code help!

Jonathanpitzl

Jonathanpitzl

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Lifetime Membership
Hey everyone, baught an 06 crossfire 700 about a month and a half ago. So I took it home and cleaned the exhaust valves right away. Put them back into the cylinders and started it and the code came on.
I spun the servo a little bit and started it and it didn't come back on.

So yesterday we got a little snow so I wanted to test it out. Right when I got on the throttle the light came on and the servo isn't opening the valves. I limped it back to the shop and read up on some stuff to look for. The things I did are:

Adjusted the cables to spec
Tester the servo with a 12v battery and it spun both directions
Pulled the tank and checked for pinched wires
Checked if the valves are in the right way
Made sure the cables were working good

Everything looked fine

What do you think is the problem? Or what I should try next
 
Jonathanpitzl said:
Hey everyone, baught an 06 crossfire 700 about a month and a half ago. So I took it home and cleaned the exhaust valves right away. Put them back into the cylinders and started it and the code came on.
I spun the servo a little bit and started it and it didn't come back on.

So yesterday we got a little snow so I wanted to test it out. Right when I got on the throttle the light came on and the servo isn't opening the valves. I limped it back to the shop and read up on some stuff to look for. The things I did are:

Adjusted the cables to spec
Tester the servo with a 12v battery and it spun both directions
Pulled the tank and checked for pinched wires
Checked if the valves are in the right way
Made sure the cables were working good

Everything looked fine

What do you think is the problem? Or what I should try next
Click to expand...
mine did the exact same. Would turn with 12v but not on the sled, 2 new cables and servo motor. My cables were ok but @ 7000miles was time
 
Make sure the servo motor shaft is not 180 degrees out of rotation when you reinstalled the servo spool

You will see an index mark on the end of the shaft (Pull off the nut and servo spool) - You will also notice an index mark on the housing behind the shaft at around the 2 pm clock position

When the servo shaft spins , it spins from around 11 am - 2pm clockwise position opening the valves - Even though you might have the servo spool in the correct orientation , the shaft behind it could bee off 180 degrees

Sets off a check engine light every time if off 180 degrees
 
Last edited:
 
Did you do the potentiometer test in the Cat document I posted in your previous thread? Mine was doing the exact same as yours, but failed to reach 4700 ohms in that test.

I was in the middle of a trip in revy and had to buy one from a dealer ($500 - ouch) but there are lots on ebay for a quarter of that.
 
In your first picture , dont line up the index marks

Put the servo shaft index mark at about the 10-11 am position - When you put the cables on your servo spool and reinstall back on the shaft make sure they are/stay in that 10-11 am position - The valves will bee closed

Now when they open , servo spool rotates clockwise to the 2pm position , THOSE INDEX MARKS WILL LINE UP !!! You wont bee able to see that of course because the servo spool will be covering the index mark on the end of the shaft
 
10-11 am Servo shaft index mark - Valves closed

Servo rotates clockwise , then THOSE INDEX MARKS WILL LINE UP , Valves open

Rotate that servo shaft index mark back to the 10-11 am position before installing cables and servo spool - Make sure it stays there , cables might have some slack , but valves will bee closed

Then rev up motor and get back to us
 
Cables adjusted to 34.5 mm equal length - Are you measuring correctly ??? Can you pull manually by hand on each cable , pulls out smoothly and snaps back with little resistance ???

Engine off - With the cables on the servo spool , manually spin the spool clockwise until the valves are open (Index marks would bee lined up)
Start the sled and see if the servo resets itself

Potentiometer Test
��NOTE: The following test should be made using
MaxiClips (p/n 0744-041) and the Fluke Model 73
Multimeter (p/n 0644-191) set to the ohms scale.
1. Remove the servomotor from the snowmobile.
2. Connect the red maxiclip and meter lead to the
black/white servo terminal; then connect the black
maxiclip and meter lead to the yellow servo terminal.
3. Rotate the servo pulley counterclockwise. The
ohms should increase as the pulley is rotated until
it reaches 4700-5000 ohms.
4. Continue the pulley rotation, and there will be a
small area in the rotation at which the ohm reading
will disappear; then it will return again.
5. Continue the pulley rotation, and the ohms should
appear at a very low value but will again increase
to 4700 ohms. This is normal operation.
6. Install the servomotor.
��NOTE: If the servo operates correctly and the
potentiometer test is correct but fails to operate
when connected to the ECU/CDI at the designated
RPM, replace the ECU/CDI.
 
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Out of curiosity , if it still throws a check engine light , and those cables slack up again like in your pictures, rotate the shaft 180 degrees opposite from what I previolusly mentioned , reconnect the cables on the spool and see what happens
 
I remember I took the motor apart and I think I slipped the gears inside the servo, would that matter and is there marking to line them back up?
 
Before you go on a wild goose chase with the gears get a multimeter and test the potentiometer. If it does not make between 4700 and 5000 ohms you need a new servomotor.
 
I did the potentiometer test and it was in spec, then a guy told me to take the cables off and rev it up, so I did and it spun 3/4 or a rotation clockwise and stopped
 
What is the exact way you are adjusting your cables.

Like I said , it's either 180 degrees off on that shaft or your cables are not adjusted correctly.

When you manually pull on each cable by hand are they smooth and snap back. How are you measuring.

Wish you where closer
 
They snap back right away, and I made a gauge out of a bolt like the guy said he made and made it 1.35 inches long
 
And your removing that clip and of course pulling those cables out of the Servo Housing and then measuring

Click and blow up that picture



Make sure to pay attention to step 2 it is critical. Most have went to re install the cables and rotated the servo counter clockwise even more to get the cables back on and it was 180 degrees out of whack when it should have gone clock wise. hope this makes since...just mark the servo with a marker so you dont make a mistake...if you do your check engine light will come on and flash 6 times indicating a servo failure

APV_Procedure.jpg
 
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