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need help! engine noise, skyrocketing RPMs

  1. #1
    martyk martyk's Avatar
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    need help! engine noise, skyrocketing RPMs

    ok so looking for someone to possibly give me a hand. Heres the story:

    I have an 03 kawasaki 636 with under 12,000 on it, over the winter i decided to tear down and sandblast the frame, subframe, and upgraded rear swingarm (its off an 07 636) as well as upgrade the rims (from an 05 636) . only real "mods" i did was manual CCT and block off plates for the top of the motor and changed the oil. ok....

    the dilemma:

    turn the key to power up and i get alot of mechanical noise from the right side just under the airbox where the throttle bodies are, there is a little motor there which buzzes, which it is supposed to do but it goes a little haywire and abnormal then stops, ok whatever

    i go to start the bike and it starts then the RPMs skyrocket within seconds so i hit the kill switch, (the bike is currently sitting upright on front/rear stands) thinking maybe the idle adjuster is off i back it out a few turns then try again, same result, get to the point where there is no pressure on the point where the idle adjuster contacts. seems like it is also running very rich? pretty much stinks like a lawn mower. So this is here I stop and decide i am going to post on here and hope someone more mechanically inclined may be able to help me. i am more then willing to pay if it ends up being something where you get your hands dirty (i guess at least i can spring for a case of beer of your liking). So if anyone is near norwood or feel like making the drive here post up or send me a PM. i work nights so sleep from about 8am till 4pm with tuesday thru friday off , technically.

    thanks in advance to anyone who may be able to help

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  2. #2
    Just Registered Origin's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    Have you checked to make sure the throttle cable isn't being pinched?

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  3. #3
    martyk martyk's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    i havent but will check, however i dont think it would do what its doing if it was wouldnt explain the smell, this is fahking annoying

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  4. #4
    Newbie Linteau's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    Do you have a after market pipe? I have a feeling that when you did the block off, that's what's making it run rich. The reason I think this is, I did block offs on mine and it's also running rich.
    I need to find a dyno around me get a good tune. Again, this is just my thoughts.
    As for the idle and noise, could you cct be to tight?

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  5. #5
    Super Moderator TheIglu's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    SHIFT!

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  6. #6
    martyk martyk's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    oki should specify maybe...im not even riding at this point , bike is up on stands.
    i just have a chopped yoshi pipe, i think its gotta be throttle bodies, im about to go out to the garage to check on that

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  7. #7
    martyk martyk's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    pulled the code, code 62: subthrottle valve actuator malfunction, wiring open or short
    figure this is my problem...time to trouble shoot this

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  8. #8
    martyk martyk's Avatar
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    Re: need help! engine noise, skyrocketing RPMs

    problem resolved, subthrottle actuator unplugged, secondary butterflies removed

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