Well I poked around it a bit, and got to know her a little better. I downloaded the manual, wiring schematic, and the carb rebuild pages. Took off the airbox resealed it and put it on a shelf. Tried to fire it up and I didn’t know why it wouldn’t fire at the time. So I bought those crappy carb rebuild kits that don’t even have all the proper jets. I thought this would solve all my problems (facepalm). I didn’t listen to what everyone said here and what was on Cliffs site. I just took apart the carbs (not fully) sprayed carb cleaner around and just swapped the jets with the ones in the kit. Threw it back on the bike at this point I didn’t even have a new battery in it. I was using the one it came with and a jump pack or a shop battery charger/jumper. Tried to start it without the airbox, nothing. I cranked the hell out of it with the shop jumper spitting out all it could it was set at the highest voltage which was labeled “jump” 200Amps. I saw smoke coming from one of the ignition coils and oozing what looked like wax. So now im shopping around for ignition coils and new OEM ones cost a lot more than I wanted to spend at the time. I ended up getting used ones from Neanderthal Cycle Salvage out of Cali. Tested them and they were on the high resistance wise plus they were butchered as far as wires and connectors. I also fried the igniter. I purchased new Accel coils and a used igniter from Neanderthal.
While I waited for those to come in I did some reading. I checked the valves which were smack dab in the middle of spec and I took apart the carbs again this time fully. And now I break one of the float pin posts. I couldn’t find a replacement so out of a fit of desperation I go to my local Suzuki dealer. Wonders they had one just sitting on a shelf from a 750 which by this point I knew would fit give or take a jet or two! So I change out the jets, diaphragms, etc. benched synced the carbs threw those on installed the new coils w/ relay mod (poorly at the time), new battery, intake boots, intake o-rings, airbox rubber. I still had not purchased a vacuum gauge to do a true sync. But still did enough reading on here, posting, and half listening. It lived and I rode it a bit, and then got the paperwork sorted insurance etc. At this point I’ve been riding for about 3 months on my brothers 86 450 Honda Rebel. So I take it out on its first virgin real ride.
The plan was to ride into PA on RT-78 take off my helmet and ride 611 up the Delaware River to RT-80 and back home total of about 150 miles. The ride was great until the last 6 miles; it crapped out on me in NJ traffic. I got a tow home and I poked around the igniter literally cooked, fuses blown, bulbs, battery, and some connectors. It was a mess. I thought it was just a faulty igniter for some reason. A member here had a few with the same part # so I bought 3. After tinkering and 2 igniters I found it was a faulty R/R and a loose connection from my bad relay mod which probably caused the bad R/R. I read the stator papers and actually listened to people here trying everything they suggested, well short of the sarcasm which didn’t happen much. Just so I knew it wasn’t whatever they suggested. I did a true sync, and rebuilt the carbs properly, new tires cause of dry rot. And now its riding better than ever. I skipped the cursing, bleeding, snapped bolts, long wait periods for parts and the back and forth so this is the short version of the 1 ½ yrs of the project.
So in closing I must say read read read. Listen to Cliff’s mega welcome. If you still don’t know ask, and lastly take your time.
Comment