No Limit Powersports Posted September 20, 2004 Report Share Posted September 20, 2004 Ok sorry about the long post but you'll need the history. My 03 (see profile for list of mods) will start 1st kick every time idle perfect. But as soon as you rev it up it seems to have a rev limiter at about half throttle (not the parking brake limiter of 2300rpm more like 5000-7000rpm). It kinda even seems to stop firing on just the right side at the f**k up point ???? It seems like this all started when my flywheel came loose and I put it back on then everything was fine then it came loose again twice in one day so I put some loctite on and a lockwasher no more problems here. Then it started the same kind of cutout that this loose flywheel was producing again but it wasnt loose anymore?? So I started checking things... To make a long long long story short heres what Ive done with no success. Checked reeds fine, completely cleaned carbs, replaced with working units(stator and flywheel,coil,cdi--fixed or stopped temporarally (so replaced fixed for a short period then started again), tors unhooked--parking brake switch cut,both carb plugs cut,throttle switch cut, black box uplugged under front left of tank) This problem has been very intermitten since the beginning and Im running out of options to try to fix. The bike has 150lbs of compression on both sides with 17cc domes and a high end port job. With the way it started messing up it leads me to believe something failed and not a jetting problem. I have been fighting this thing for over a month and I really need some help. If any body has any suggestion it would wouldly be greatly appreciated. Quote Link to comment Share on other sites More sharing options...
fixitrod Posted September 20, 2004 Report Share Posted September 20, 2004 Seemed someone had a similar problem and adjust the gap between the pickup coil and flywheel. Maybe your flywheel damaged the pick up coil or moved it. Quote Link to comment Share on other sites More sharing options...
ledofthezep Posted September 20, 2004 Report Share Posted September 20, 2004 Well it looks like you've covered your basis...I was going to suggest checking the pickup coil on your stator after the flywheel came loose, but I see you've already replaced it so that's out of the question; but did you make sure the gap on the pickup coil was adjusted properly? Other than that, almost sounds like a jetting/clogged jet issue. Quote Link to comment Share on other sites More sharing options...
ledofthezep Posted September 20, 2004 Report Share Posted September 20, 2004 Seemed someone had a similar problem and adjust the gap between the pickup coil and flywheel. Maybe your flywheel damaged the pick up coil or moved it. Ya posted too quick, didn't see your reply 'til after my post. Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 20, 2004 Author Report Share Posted September 20, 2004 (edited) well I replaced the stator assembly with a working unit which includes the pickup and no difference but I think I set mine at .20 if this is not correct somebody please correct me. I have completly went through the carbs twice but this doesnt mean there right is there a possiblitity that a float level could be out of adjustment and cause it to starve at a certain rpm. What is the float level supossed to be at? And how do you adjust it? Is there a rev limiter other than the one built into the tors and if so how do you wire around it? Edited September 20, 2004 by bansheestang Quote Link to comment Share on other sites More sharing options...
racer Posted September 20, 2004 Report Share Posted September 20, 2004 there is no limiter. im not sure on how to adjust float height but i think that if improperly adjusted it can cause similar problems. Quote Link to comment Share on other sites More sharing options...
frocashmoney24 Posted September 20, 2004 Report Share Posted September 20, 2004 are you sure your tors is completley unhooked?, carbs in sync? opening all the way Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 21, 2004 Author Report Share Posted September 21, 2004 Ok last night I changed my right carb with a working carb just to eliminate any possiblities of that no change. I unhooked the tors already like mentioned in my first post. My carbs are in sync (made the balls show in the windows on the carbs at the same time. Do you have to close any circuits after you unhook all the tors. Next I guess Ill take the flywheel off again and check and recheck all of that. Please keep the suggestions comming I have a feeling its just something simple I not seeing?? Is the built in rev limiter that is in the tors system in the control box for the tors or is it part of the cdi. And does anybody know how it works. Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 21, 2004 Author Report Share Posted September 21, 2004 Has anybody ever heard of the flywheel magnets coming loose from the outer part and if so what did it do when it did. Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 22, 2004 Author Report Share Posted September 22, 2004 Nobody has any other ideas? Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 29, 2004 Author Report Share Posted September 29, 2004 Ok guys I hate to admit it but I took the air filter off and it seem to clean up (and yes I had tried this before but I guess it must have been fouled) even know the damn thing only had like 3 rides on it I recharged it and it seem to run good again. So last weekend I was riding and after about 3 or 4 passes the stupid thing started cutting out again only this time its not near as bad. So I went ahead and leaned her out a little (raised clip one notch to 3rd and dropped mains down 2). Went for another ride no change still sounds like its cutting out. Any suggestions now?? Quote Link to comment Share on other sites More sharing options...
BenBB Posted September 29, 2004 Report Share Posted September 29, 2004 What does the plug look like on the right side? And have you noticed any loss of tranny fluid? If I read your post right you said the right side missfires at upper RPM's, since you've ruled out the coil, my next guess would be the right side crank seal leaking. You'll need to do a leak-down test to find out for sure but the plug condition (compared to the other side) or oil loss could be a good indication. Good luck. Quote Link to comment Share on other sites More sharing options...
No Limit Powersports Posted September 30, 2004 Author Report Share Posted September 30, 2004 I did plug checks at idle and mid and wot really dont look bad mabey a little lean now after the last down jet but the plugs are not different. The thing is, this thing has several hours on it since it started messing up so I dont believe that it has a leak or it would already be burnt up. Plus after I took the filter off the miss got better with an air leak (lean condition) this doesnt add up . I cant tell if the miss is oughta one side or the other now. The damn thing will run and rap out but its still missing. Iam running 320 mains stock pilots and needles on 3rd clip with 2 turns on the air screws (see below for mods). I was running 340 mains and needles on 4th clip. As far as the porting goes it is a high rev port job not going to get into the dimensions but its opened alot. Not even sure that it is a fuel problem now but with a different filter on (dirtier) the miss seemed to get worse WTF. It ran before with a 340 main and now it wont 320 seems way lean to me anyway. The plugs actually dont look bad Ill post some pics of the plugs later you tell me what you think??????????/ Quote Link to comment Share on other sites More sharing options...
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