Do you have a dremel?....my suggestion....put a greased up rag right down below that actuator arm in there.Dremel off those pieces that are still in there.WATCH where yer flakes are going.I'd apply the rag deal to all stacks at on time.Just so any 'fly over' of shavings will get caught.Grease the inside of the barrels there as well.You should be able to remove CAREFULLY any piece that's left over from Knucklhead's surgery.Take yer time...go slow.Grind down flat the screw that's holding the "chip" in there.That should save you from potentially having to BUY a new throttlebody and a sych as well.They will come off of there...the chips.Mine did.With no problem at all.(one of my screw heads stripped out)...had to grind it off to remove the plate completely.All the small chips and such stuck right to the grease...just wiped it out good and it was okay.You want that rag down in there so the pieces don't get down to where the plate edge is sealing at the intake.Shouldn't have any problem if ya just watch what yer doing there.Put that grease anywhere you think the chips might fly off to.Remove those rubber stacks there.Grease that area up also.If ya go slow and grind lightly,you shouldn't get any fly over stuff going on.
DO NOT ALLOW THE THROTTLE TO OPEN WHILE DOING THIS!!!!!!
She's got a PCIII on there....your stumble sounds like a fuel mix issue.I'd say a good remap...she should be just fine.You need to verify what type of PCIII is actually on there.IF it's the "non race" model....you WILL NOT be able to map the lower range of the rpms...from 5000 on down.Look on the Dynojet website...."powercommanders"...there will be TWO versions showing...a California model...the EX....and the Race Version.You don't want that EX model.The Powercommander unit should be accessible to you on your bike...probably sitting under the left ram duct cover.Somewhere around there.Look on the side of it...the model number.
You should try to avoid grinding off the pieces of the plate that's still held on by the screw(s).Only the screw head itself.The piece(s) will come loose once the screw is ground down.Use some needlenose pliars if need be to lift the broken plate pieces from the actuator arm.Once the head is down far enough,you can probably work those pieces loose,and no further grinding should be necessary IMO.Natch,you can grind the remaining screw shaft down IF you want...I didn't.It was locktited in there,so I left well enough alone.
* Last updated by: blue07 on 5/30/2011 @ 3:43 PM *