Exhaust Flap Servomotor - jammed open - ££££

So a few weeks ago I returned from a long Euro trip, having had an engine management warning light illuminated on the dash for the whole trip (see " Ongoing experience from hell with a BMW workshop "!). The light first came on on when I stopped the engine for the first time after leaving the dealership (following fairly extensive engine work), en route to Eurotunnel.

I was finally able to get the bike in to another dealership today (the lead times round here are horrendous). I was shown the diagnostics readout "DME Exhaust flap servomotor, adjustment range", and it was explained that the exhaust flap valve was jammed open... not mega serious, and I don't really understand what it does - mainly about noise suppression I think? - I certainly haven't noticed anything wrong with the bike... but in true BMW tradition, there's nothing serviceable, and unless the mothership possibly agrees to a goodwill repair (highly unlikely as I'm out of warranty, didn't buy the bike new, or from a dealership, yadda yadda yadda) I'm looking at a £1600 bill. Jeez, Louise...

Can anyone shed any light on this for me? Does it actually need fixing or can I carry on regardless? Is it something that can be unjammed with a bit of elbow grease and ingenuity?

The other point of interest is that the engine management light was off when I rode home this afternoon - first time in 3,000-odd miles. I'll check this with the dealership, but I'm assuming the workshop wouldn't have somehow disabled the light? And the valve has miraculously (albeit probably temporarily!) cured itself?

What are they telling you is causing a £1600 fault?

Is it the servo motor not moving the cables to the valve OR a stuck valve?

The valve is easy to access, either under the cable cover above the valve OR remove the exhaust end can and it is visible.

Remove the cable and confirm level of movement and make sure it is free to rotate.

Pretty sure a good spray of brake cleaner/wd40 should get rid of any muck.

I spray mine with ptfe/high melting point grease and make sure as well as manually rotating the valve it also moves up and down on the axis spindle pins where there is a little movement.

I do wonder if using Shell V power (99 octane?) rather than supermarket E10 95 octane is better at keeping things clean from carbon build up. I also use fuel injection cleaner which I hope is helping.

It must be a "known issue" as before I was offered any px value the bike was checked for any warnings in the memory for the exhaust valve but no test ride required!

After getting my 68 1200rs, I had done some reading about these flapper valves sticking, so when I fitted aftermarket exhaust, scorpion, I ensured the valve was open & removed the cables between it & the servo.
Have not noticed any difference, slightly louder, but that & the looks was why pipe was swapped.
After a service recently at local independent, I managed to get local dealer to reset the service schedule & the mechanic did mention there was a warning for the valve & he cleared it for me, I never had anything up on dash.
So, you should maybe go for solution wessie suggests, i am thinking of doing same

Zitat von Dave H im Beitrag #3

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Pretty sure a good spray of brake cleaner/wd40 should get rid of any muck.

I spray mine with ptfe/high melting point grease and make sure as well as manually rotating the valve it also moves up and down on the axis spindle pins where there is a little movement.

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Thanks a lot guys, especially Wessie - that's all very illuminating.

Certainly can't see me going back to BMW for a £1600 repair over this - bizarre!

Without knowing the first thing about what the valve was or did, I did ask the tech whether this was one of those items that a hands-on owner could dismantle, clean up and reassemble rather than going for the standard BMW solution of simply renewing everything in sight, with stupidly expensive components, and got a 'Not really'. Will certainly give that approach a go when I have a moment though.

The valve is not removable as it welded into the exhaust tubing, but can be lubricated.

See https://www.youtube.com/watch?v=RotyfH_wBLY

I check this once each year along with the drive shaft joints.
So far no issues in 6 years.

Alan

Zitat von Freddyfruitbat im Beitrag #6

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I did ask the tech whether this was one of those items that a hands-on owner could dismantle, clean up and reassemble rather than going for the standard BMW solution of simply renewing everything in sight, with stupidly expensive components, and got a 'Not really'.

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Should the flap run through a self test/clean when the ignition is switched on?

I currently have the tailcan off so I thought I would check the valve. I expected it to open and close when I turned the ignition on but nothing happens. It's in the open position and seems to be free.
I've recently had a 12k service at the local BMW dealer that I bought the bike from and they haven't mentioned anything about it.

Every time you start the ignition, part of this, with the speedo 'sweep' is an open/close on the valve/stepper motor.

I take the black plastic cover off and spray the assembly below the two cables as it rotates, also the piece underneath where it protrudes in a drain point.

Not had it confirmed on the forum(I am servicing bike in a few weeks and will check/photo) but can anyone see where the flap is 'stuck' when this fails?

Is it the shaft or the valve flap catching on the tube sides restricting movement, IE. a build of carbon that can be cleaned off?

If you take both cables off, use a few elastic bands to keep them in tension (so they have no chance to lose location at the stepper motor) and see thet they are moving. Maybe hold them and get another pair of hands start the igniton?

My mistake, stepper motor/actuator/thing-a-me-bob/widget! all I meant was to confirm both cables are able to show a forward/back motion are moving.

I guess you could even have dirt/rust in the cables which are jammed up with debris.

You can just disconnet them and check for valve "free movement" and if it is too tight causing the issue

Removed my stock exhaust after 24 miles . Installed Black Widow with the dongle bypass , and removed the motor . Upon motor removal one of the cables lock nuts was lose and cable off the pully . Factory missed getting the cable adjusted and tight . Glad its all gone . RS with Full exhaust.jpg - Bild entfernt (keine Rechte)

Upon closer inspection of my flapper it would appear that the servo isn't working. The cables and flapper are all free and you can feel a click when the ignition is switched on but nothing else happens.


EDIT
I've just seen this on the R forum so I guess I'll leave the cover off and just see if the flapper moves. But I need to put the tailcan on first!
- With the 1250 the flapper only does that check-upon-power-up either after 30 power ups or 30 days.

https://www.r1200rforum.com/threads/does...51/#post-629024


EDIT 2
It would appear the 30 times thing is a thing. I've just put the tailcan on and, the first time I switched it on, the flapper did it test. Which I assume was pure coincidence. Off/on and no test but flapper operating when the bike was running.