The "Turd" is down and out(head gaskets & other stuff)

[AApple]

Not very productive today. Spent far too much time re-doing stuff that I had wrong. Both throttle cables & the tach cable had to be re-routed, for instance. Just stoopid crap like that took up a fair amount of time, and aggravated the hell outta me.
Got the stator wires soldered up. Used solder type butt connectors, so they're crimped AND soldered, then heat shrink tubing on top.

GL1100201

• AApple
• Feb 14, 2016

Stator wires-butt connected, soldered, heat shrink.

GL1100203

• AApple
• Feb 14, 2016

Stator wires-butt connected, soldered, heat shrink.

Oh..and lookie what I found!

GL1100204

• AApple
• Feb 14, 2016

Damn....

Right where I friggin left them... oh2:

Raditater and grill installed, fan wired, some chrome bling polished and installed. All engine mount bolts in and tight, except the looong one that goes across the bottom/front. That one has to wait until I'm ready to install the crash guards/floorboards/exhaust.

GL1100207

• AApple
• Feb 14, 2016

Mostly finished.

GL1100208

• AApple
• Feb 14, 2016

Rad & some bling on

GL1100209

• AApple
• Feb 14, 2016

Getting closer...

I seem to have completely lost the two long bolts that hold the air cleaner basket onto the carb plenum. I looked for those damn things for at least an hour before giving up, and finding some temporary substitutes. I'll get two correct bolts tomorrow.
At this point, it's pretty much ready to fire up...except there's no oil in the engine yet. Need to pick that up tomorrow, too. I'll get the exhaust hung, and see if the dern thing will even run before doing much more. Once I hear it run, and make sure there's no leaks, I'll be on the home stretch. Still got tons of cleanin to do on the tupperware stuff, and the rest of the chrome/guards/brackets and such.

 

[slabghost]

That's one shiny turd! Put the dang sparkle plugs in where they go but check to be sure no debris fell in.

 

[Steve83]

She's a beauty now, to be sure! By the way, the small tubes between the carbs are for the accelerator pump circuits.

 

[AApple]

Steve83 » Mon Feb 15, 2016 12:17 am[/url]":ctdhdww7]
She's a beauty now, to be sure! By the way, the small tubes between the carbs are for the accelerator pump circuits.

Ya...I finally figured that out while putting it all back together. :yes:
Tanx fellers....it's been a rough journey at times, but I'm semi-determined to get it finished, and rideable again in the next week or two. :beg:

 

[Denver]

Yea that's how we wind up understanding how this stuff works. :good:

 

[toytender01]

Check for those missing air cleaner bolts where those missing spark plugs were hiding for so long :smilie_happy:

 

[Ansimp]

toytender01 » Tue Feb 16, 2016 6:21 am[/url]":1z0l3cxy]
Check for those missing air cleaner bolts where those missing spark plugs were hiding for so long :smilie_happy:

I think they just swapped hiding positions :smilie_happy:

 

[AApple]

AAAAAARRRRRRRGGGGGGHHHHHH!!!!!!!

So.....I get erl, and coolant. Fill rad & engine. Just wanted to see if this turd would fire off and run for just a minute or so....
What the hell was I thinkin? oh2:
F :sensored: g thing won't start....just spits & farts. It's like deja-vue all over again....
Plugs are firein, 150psi compression.

 

[Steve83]

Firing order? We've all crossed plug wires before... Do NOT work on it when your pissed!! It's too tempting to destroy things!

 

[dan filipi]

Firing order was my first thought also.

 

[AApple]

reallykittie

• AApple
• Feb 15, 2016

:ahem: :BigGrin:

Plug wires are still in the factory harnesses, each side wrapped to the side of the frame they fit. Plug wires not mixed up. This ain't me first rodeo...tho I don't know why I keep entering....I never friggin win.... :head bang: :hihihi:

I have a sneaky suspicion it will be something with the pulse generators...again. I'll pull the cover off tomorrow evening and take a look. I did have a question about the rotor tip/pick-up coil gap, so it's prolly something to do with that.....since it's in such an easy place to get to..... :rant:


Nappy time for bonzo now.... :lazy: :lazy: :lazy:

 

[Ansimp]

Too bad Joel, have a nice nap and I am sure that you will soon have it sorted :yes:

 

[joedrum]

:swoon:

 

[slabghost]

You had everything out and apart. You expected this. You must have a couple wires swapped somewhere. Rest up and it'll come to you.

 

[Denver]

Agreed, it's more than likely a wiring issue somewhere. :headscratch:

 

[AApple]

:rtfm:
Otay....let's go over the looong list of wires that have to be removed/disconnected to get the engine out:
1: Plug wires
2: Pulse generator connector
3: Stator wires
4: Coolant temp connector
5: Fan switch
6: Neutral switch

Now...we'll narrow down the list to only those wires that could/would keep the engine from firing off/runnin: :mrgreen:
1: Plug wires
2: Pulse generator

My bike still has the original plug wires/covers/seals, that seal the wires to the heads. While these seal thingys will fit either side, with the plug wires in them, they will only fit correctly on one side, unless you spin the wires around in the seals, which would also make the wires bend in a different direction. When I removed the wires originally, I flipped them up, and over the fairing bracket on their respective sides, and tied them there. The wires were not disconnected from the coils, only from the plugs. The plug wires are in the correct locations. :BigGrin:

So....according to our flowchart above, that leaves only a problem with the pulse generators/wiring(as far an electrical issues). No?
Those of you who were not here when I went thru this same idiotic thing 3 years ago don't realize that I have been down this dadgum road before....and we all had the same suggestions/thoughts as to what could possibly be the issue. I ain't fallin fer th' nanner in da tailpipe trick again( :smilie_happy: ), so I'm goin for the one thing that caused me misery before FIRST. I'm pulling the PG cover off tonite, and taking a look. I'm 99.99% certain I have the rotor bolt/washer installed in the correct way....I checked that dam thing at least 10 times before putting the cover on. The only thing I'm not sure of is the air gap between the rotor tip, and the end of the pick-up coils...this is what I think is the problem. Not sure it is, but that's where I'm leaning at this point. I'm gunna either confirm or eliminate that first, and go from there. :yes:

While cranking it last nite, it WAS firing, but it was popping/blowing flames out the heads(there is NO exhaust on the bike right now), on both sides(not a deafening backfire type noise, just lite pops...kinda like popping yer finger in yer mouth type noise). This kinda tells me there is fuel/air/spark in the cylinders....but possibly not all at the correct time. There is good compression on all cylinders, and I verified the cam timing many times before calling it good. Another bit of info, too....at times, the engine would stop spinning, or kick back...similar to way too far advanced timing, or hydro-lock. I'm absolutely certain there are NO fluids in the cylinders...I checked that while doing the compression test. It's like the plugs are firing long before the piston is at the top of the cylinder, and considering the flames from the exhaust, it appears the plugs are firing while the exhaust valves are still wide open. Which all leads me to suspect an ignition timing issue....same as last time. :doh:
btw...I don't want my replies to ya'lls input/ideas to come off as disrespectful, or flippant. I really do appreciate any/all input for anyone. I KNEW when I started this project this time it was gunna be a challenge, since I also wanted to take some time and make things purdy. I spent far too much time on the aesthetics, and lost track of the original goal of getting the dang thing running right again....losing some items in the process, as well as loosing some of my original enthusiasm. Youse guys kept me going, and continue to keep me going, no matter WHAT boneheaded move I make. :thanks: :thanks: :thanks: :hi:

If I don't find a problem with the pulse generators, I think I'll just go ahead an poke some holes in the new tires, just to get that over with.... :smilie_happy:

 

[Steve83]

When I pieced together the 1200 fuel injected engine, it just sputtered and popped. It turned out to be closed throttle plates, so I opened up the idle speed screw, and it fired right up. Are you holding the throttle a bit open while you're tryin' to start it?

 

[backlander]

If I remember correctly in one of your earlier post you questioned the air gap on the pulse generators and set them accordingly at that time so I don't think that will be the issue. You seemed to have removed plug wiring as issue but have you checked proper wiring to coil sequence firing ? Sounds to me like it is a timing issue.

 

[bronko37]

Here is a professional engineering flow chart you may find useful in your en devour.

 

[Denver]

Have you got an extra ignition module ( box) to try? :headscratch: Don't remember if that was checked out or not. :nea: Just trying to cover all bases. :roll: That's why i try to have at least one of everything to swap in the ignition system :smilie_happy: to make the process of elimination simple enough so that even an idiot like me can figure out what's wrong.:yahoo: Wow that engineer flow chart looks promising, never mind :hihihi: