Hooked up the carb sync... this is what resulted. I am not sure why I have such poor response on #2, but it is keeping me from synching the rest of the carbs. It doesn't make much sense to colortune either, until I have this issue worked out. The video states #3, but it is actually #2. But, the carbs are numbered 4,3,2,1 whereas the intake is numbered 1,2,3,4. Not sure why those crazy Japanese engineers designed it that way, but it sure does lead to some confusion.

I don't know that it's not the valves, but considering it was running pretty good before I got my hands on it (including changing the oil sodden, dirt encrusted air filter, plugs from the late 80's, drive shaft oil, coils, plug caps, new fuel filter, dielectrifying every accessible contact, and tons of dirt and much removed from the carbs x4!!!!) you'd think it would be happy now.

I'll keep hacking away at these issues as they arise.

If I never have to pull carbs again...

That was the most intensive 2 weeks I have ever experienced with a bike. Not that I've had that much experience, truly, but holy Hannah! A lot of work went into those weeks, including repetitive boring tasks better left for once in a great while. I must say, I have gotten quite adept at pulling the carbs, as well as learning a few tricks for reinstallation.

To the bike...

I put the carbs back on, cut my new fuel line to length (a POX on you, Autozone!) and gave the bike a few minutes to fill with fuel. Then, the big moment arrived. Would it start?

Success! The bike started with minimal choke (in fact, I wonder now if it would have started without the choke... I'll have to test that) and ran like a champ. Then I messed it up good by trying to sync it. I don't know whatt the issue was, but I couldn't get the carbs to sync very well. As soon as I adjusted one, the other would go out, that and a variable idle made for a very difficult sync. I still have to colortune it, but for now, the plugs are brown, maybe just a wee bit on the rich side.

The bike looks clean, (it should after spending all morning polishing it getting the layer of dust off!) and is running pretty well. Honestly, I am just going to ride it for a while. I plan to ride out to DW's house and pick up my sunglasses at some point, and maybe do a carb tune.

I feel pretty good right now, the fact that I fixed this non-running bike all by muself with my own 2 hands makes me feel pretty damn good.

So, following one of the esteemed members of the xjbikes forum, I drained my fuel bowls, thinking that maybe, just maybe, there might not be any fuel in them, indicating a blockage of some sort.



This what I found. I don't know what it is... some sort of amoeba, I think, plus, it has the ability to replicate itself, and then rejoin together.

I boiled my carb bowls in lemon juice yesterday (per suggestions on aforementioned forum) and rinsed them out well with carb cleaner and compressed air. This little splooge was hiding somewhere, though I can't imagine where. I don't know if this is the cause of the "not starting" issue, but it certainly couldn't be helping things.

I also pulled apart all the connections on the TCI box, some of those plugs were a real pain to pull apart. However, I was successful, sanded down all the connections I could reach and dabbed a bit of dielectric grease on the contacts. I can't imagine they have seen the light of day before now, considering the greenish/grey gunk all over them. It didn't help the starting issue at all, but it couldn't hurt, either.

I was able to pull those carbs off in under 10 minutes. Familiarity, however, does not make the heart grow fonder. I was calling them all sorts of names. I found that it is easier to heat up the boots with my trusty heat gun (on the lowest setting, of course, don't want to melt 'em) and then push the boots down and out, at least the two inner boots.

Be sure to keep track of which way the clamp screws are pointing. The clamps are setup to be accessed from the bottom (bunch of screws in the way up top), so be sure said screws are pointing out.

I'm soaking the carb bowls overnight in carb cleaner, as well as the brass fittings, emulsion tubes and washers. I removed the little screen portion. I can't imagine that cleaner is any good for that screen. (Then again, they are awash with gasoline all day. What gives?)

More tomorrow.

Nearing defeat...

Okay, so the bike is all put back together. Fuel tank hooked up, carbs sparkling, new plugs. Should fire right up, right?

WRoNG!!

I don't know what it could be at this point. I am ready to call a motorcycle mechanic to come over and help me out because I am at a complete loss.

I cranked the bike, used starter spray, used the choke, and nothing. It just cranks and cranks and cranks until the battery dies. I have it on a charger right now, but I can't imagine recharging your battery is doing it any favors (and certainly diminishing the life of it).

I'm thinking of just putting it away for a while and rethink things... I'm NOT tearing those damned carbs off again. If one more person tells me "Your carbs need cleaning" I am going to go crazy.

The only other thing I can think of is maybe the float level is off... would that affect the start? I don't know. Guess I'll have to do some more research.

I would like to ride it some time this summer. There is a guy I work with who works on small engines. Maybe he has an idea. Every time I see a bike roll past, I feel angst... and it makes me a little sad too.

The only suggestions I am getting from the majority of people on the xjbikes list is "clean your carbs".

Ready to hit it again...

In just a few minutes, I am going out to the garage and put the bike back together.

A good thing to remember when you are reinstalling the carbs and throttle cable, make sure the intake hose clamps are not in your way (don't as me how I know that, x2) or else you will have to loosen the clamps again, move the carbs around, and reset. If you are finding that your throttle arm is stuck, or there is no free play when you twist the throttle, this is most likely the culprit.

I'll post some pics and commentary when I all finished.

Really getting frustrated

Now I'm frustrated. I'm not sure what is going on with the bike, but it seems to be one thing after another. First it was the coils, then it was the carbs, then it was the carbs, now it's the carbs!!!

I'm nearing the point of just giving up. No matter what I do, I keep ending up back at the same place I started. I am currently installing the carbs for the third time after cleaning them again. I bought some shitty fuel line (though it was damned expensive) with a light blue coating on the inside. It's done nothing but flake away (leading to messed up carbs again and again.) Of course, I didn't know that was the problem at the time. Thanks a lot, Autozone. Way to go.

I had to stop the re-installation because it was getting to dark out to see. Tomorrow I'll be at it again. Of course, the burn on my hand isn't helping things either. HUGE blister on the palm of my right hand. Two of them, in fact.

I really hope this does it for the bike. I actually got it running this morning. Rode it up and bought some gas, but same issue (although to be honest, the pick up was scary fast) it started acting screwy and when Igot home, the bike wouldn't start again. Fouled plugs. I am going to turn the screws out to 4 and see what happens.

I really just want to ride. That's all. Is it too much to ask? Maybe I should talk with Tex from work. He fixes small engines. Maybe he'd have some ideas.

Argh!

Man, I am such an idiot!

Okay, well, I didn't do it intentionally.

I've been struggling for the past couple of days trying to get the bike to run normally. You know, put the key in, turn it on, maybe a little choke, and vrooom! But no. I had to go and do something completely stupid it defies explanation.

The last time I took the carbs apart, I neglected to tighten the bolt that holds the emulsion tube in place. Not only that, but I also neglected to tighten it's neighbor on the adjacent post. So, when I pulled the carb bowl off, I found the 2 bolts and a copper washer just sitting in the bowl, doing nothing.

Oh yeah... because of this, I emptied my gas tank into my crank case, prompting an oil change. I'll need to pick up a new filter tomorrow. Luckily they are pretty cheap.

It is my hope that this is it for carb tear offs. I was able to replace that boot that was in bad shape. I'm awaiting my other set of boots that should be here in a couple of days, but I am not going to wait until they arrive to ride the bike. I'm half tempted to go out there tonight and finish it. But, best to wait til it's light out.

More tomorrow...

Killing me...

I don't know if it's just my imagination or what, but there seems to be a lot of bikes on the road, more than in days past. Or, maybe it's because mine is still sitting in the garage awaiting the final screw and boot to make it road worthy.

Well, that and the carb tune, which REALLY needs to be done. That shoud arrive tomorrow (10days+ since I ordered it, and Morgan is known for their expediency in shipping those things.

Needless to say, the next week is going to be a busy one.

If:

* I get all parts and supplies for the bike, I could have it on the road by late Tuesday.
* I don't run into any problems getting it all tuned up. That valve clearance issue is starting to worry me...
* Should have checked float levels (may still do that) and bench synched the bike (not looking forward to pulling carbs off again, but will if I have to)

It's beautiful weather today, and is supposed to rain a lot in the coming week... which I suppose will give me ample time to get the bike up to throttle zipping standards.

Polished the side covers again. Very shiny.

Ran the bike for a bit. The plugs are still fouling pretty badly, but considering how far out of synch everything has to be, I guess I am not surprised. I have a new set of plugs ready to slap in, once I have everything in hand.

Ha! I won set of carb boots on ebay for about $20. About the same I paid for one carb boot from chacal. Of course, these are used, and it doesn't appear that there are any clamps that come with them. If nothing else, I can sell these on ebay myself.

Come on, Monday.