516,, 2013 flood victim

[excess.11]

Does this bike have a Clutch switch and a sidestand switch? If so have these been fully tested and eliminated?
Just go for a run on the bike with the fuel cap not locked down to quickly check if it s a blocked fuel cap vent hole.

[steptoe]

that was another thing we swapped Jeff,,
 3klm  wouldn,t effect the volume of air in a half full tank, but we can check yes,
nice to hear Bretty will do

[excess.11]

Breaking down ....running sweet......intermittent cutouts.......starting.........not starting..........running on 3 cylinders.
The TCI unit has the ability to do all these things...along with the connections into it ..........and away from it.
 Have you changed it over for a known working unit?
Is the vent hole in the fuel cap clear?

[BrettS]

Damn, Geoff. All I can offer is that it seems the tip over switch can simply be removed, no bypass needed. At least it worked when I unplugged mine on the weekend.

[steptoe]

                                                            SO HERE,S THE WASH UP


                                                    it still doesn,t go
we replaced the coils with bench tested good coils
we replaced 4 plugs,,, just because
went thru a heap of electrical connections and tightened if they even moved
                                                                    hit the button and away she went, smooth and crisp almost,
balanced carbs, set air fuel mix and she was running sweet,, about bloody time

put her on the road for a 6 klm test ride, go!!!!!!! bloody hell it goes,, about 4 klm in it started coughing like it was light on fuel or had a wet distributor {yes I know it doesn,t have one, that,s the kind of run rough}  got it back to the house as she ran out of puff

we sat there looking at it for 5 minutes willing it to fix herself,, hit the button and away she went again, smooth, crisp, and sweet, we start thinking diaphragm in octty and discovered a kinked vacuum line, out we went again so route so as to have something to gauge by,
a successfully run this time no issues,
gave it to Len {the owner] for a run, he was gone 20 minutes plus, must be going great and he,s gone,,

                                                                                NO SUCH LUCK
it stopped 4 times on him. twice he thought it wouldn,t wind over quick enough to start, once back we moved and jiggled everything we,d moved and jiggled under the explanation that someone hit the kill switch,
same as the other times, 5 minutes had elapsed we hit the button and away she went again, this time I followed on my bike, 3 klm into the run it stopped cold again, no warning cough, splutter just stopped, so we sat there for the unexplained 5 mins, still nothing, probably from compression lock was my thought, so we tried push start, it ran on 3 for about 2 klm then stopped cold again, 
the next 3 klm it was pushed   

so our next thoughts are bypass tip over switch, replace the pick-ups with a 3rd set, replace the reg/rec with a 3rd, charge the batt to full, replace the stator windings with another, bypass kill switch and check any other bloody thing we/you  can think of

the hardest thing now is up to this point I,ve been able to control how much money has been spent, once it leaves my place to another w/shop, how long is a piece of string, and ol mate can,t afford that sort of dollars and don,t really have any more time to spend on it, I have other jobs backing up ,,
                                                                         what to do

[excess.11]

Throw in some new plugs for good measure as well.

[steptoe]

1 more w/shop day,
it just pisses me that I can help others with their issues, and can,t get a bike in my own shed running
makes you feel like you talk s$%T mostly,
we,ll get it, have just been thrown a lifeline by TIM {if your reading ring me} with some brand new Z ent coils so we,ll see how that pans out

[makzy]

Don't give up Jeff, The end is nigh!

[Jonesy :-)]

Steptoe,
As deflating as it is to have to hand back the floody at not 100% running properly, you have to be commended for your efforts and genuine spirit of volunteering and helpfulness. I take my hat off to you for saving what would otherwise have been destined to be a rusted piece of flood damaged junk.

[steptoe]

thanks Jeff, hopefully the couple of spares Ev is dropping off come up trumps and it,ll all be good,, failing that I spose a set of MikesXS coils may have to be sourced

[excess.11]

Steps.............If the coils have copped a soaking............I definitely would not have reused them.
Any ingress of moisture...... would be difficult to say the least....... to dissipate...as well as firing them up if moisture was internally present would of caused flashover OR shorting of the windings and carbon tracking /deposits.
A resistance test is one thing .........but actually passing power through components ......especially when it s high voltage will bring any fault to the fore.

RESISTANCE TESTS USE MINIMAL VOLTAGE THROUGH THE COMPONENT BEING TESTED.
WHEN COILS /ELECTRIC MOTOR WINDINGS ETC ARE BEING TESTED FOR "INSULATION RESISTANCE" YOU MUST USE AN "INSULATION RESISTANCE" TESTER.

[BrettS]

Do you want me to have a go?

[steptoe]

this #^&($^% bike doesn,t want to go home,
the slight stumble turned out to be a naffed idle jet, {long story} but trying to get it out I snapped an easy out in it, there goes the carb body,

had to clean up another body, pulling 2 sets of carbs apart and re-assemble,  fine I says I can do this, put them back in the bike with Ev present, hit the start button and the warmer it got the worse the popping back thru the carbs and flames out the exhaust at it,s hottest

it didn,t matter what we did we couldn,t get rid of it, so the carbs came off again and the originals went back on after a bit of working up and down of the air fuel mix screws that had been soaking since they came out {the reason they came off in the first instance} and the popping persists

the only thing on this bike that went thru the flood is a set of coils that come up right with multi meter readings and a reg rec that we replaced with no different result,

deadset I,m over it,,,,

because Ev gets home at a decent hour of an afternoon he has taken all the spare coils I have to be bench tested by the professionals this week and will be swapped the next w/shop day

failling that {much to my disgust/dissappointment} the bike will be handed over to Len and he will have to pay for some one to do what ever, 

there,s nothing out of wack with the motor,, the fuel systems are the cleanest I,ve ever done, another harness,, everything else has been replaced,

it gets 1 more w/shop day

I have done all I can,, 

[Jonesy :-)]

So now you can get on and do that leaning side car  good work on finally getting the floody going

[steptoe]

sorry, been busy,
       the wash up ------------------------- 3 plug caps were cactus,, readings were not good, couple of plugs were also kapootski,
mind you it took some getting to this end though, as usual Ev came over and started swapping bits checking others and here we are,
      took her for a 10 klm run,,,,,,,, very strong, a slight stumble off the line {but we can fix that}

all in all I,m comfortable in saying she,s ready to go home ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,                         
                                                                           
                                                                                                     FINALLY