Shim size going up?!?

[tom203]

Bad igniter?

Well, he did say he had deep blue spark on all four- hopefully at right time.

[chef1366]

With the weird valve clearances you possibly have a bad camshaft.

[Steve]

Well, he did say he had deep blue spark on all four- hopefully at right time.

and hopefully back with the right wires to the right plugs.

... flipped the plug wires and no change (number 2 to 1, 3 to 4, 1 to 2, 4 to 3) ...

.

[esmithers]

Ok good point chuck.. i will remove the exhaust and blow it out to make sure there are no obstructions. if this turns out to be it, i will **** a brick and feel like a fool.

rereading what i wrote Steve. i notice i didnt correctly explain my Coil procedure. so here goes. the left coil fires number 1 and 4 cylinders. right coil fires the number 2 and 3 cylinders. all i did was remove the wires and had the right power 1 & 4 and left power 2 & 3. Additionally i also had the plug going to 1 and 4 switched. just swapped the sides. all this created no difference. If this incorrect please let me know. i was understanding that left fires 1-4 and right fired 2-3

Chef: camshaft look cleaned and unlblemished, no wear to be seen. also bike shows 13100 miles on ODO. though that means nothing but cam looked straight and it was engaging the shims to push the valves. Ignitor was replaced when i originally got the bike and could not get it to fire the plugs. to include the R/R unit and Stator. all brand new except the Ignitor. and one forum member stated on here that Ignitors are not very prone to malfunctioning. so i replaced anyway and it cured the problem (this was not a case of poor connection either.)

So just spoke with a buddy of mine who is a FAST cert tech. and was told that the head maybe cracked/warped or gasket is blown. I told him great i have a yard ornament that will rust till i will drop money into a 650.

I think i will just go ride my Madura down the road to feel the breeze through my hair

[tkent02]

my wife has made it clear that i have invested too much time and money into this bike and suggesting i get rid of it. we all know when the wife is suggesting its more of command than a request.

She can be replaced.

[Ghostgs1]

Seems like the head would have to be good, you have pretty good compression numbers. I guess you might try a cylinder leak down test to be sure. I wonder if Chuck might have something there. Wouldn't take much to do a lot of damage to the exhaust flow.

[lemonshindig]

+1 clogged exhaust. There really isn't much that is common between 1 & 2.

Also, it COULD be a bad head gasket, depending on how you did your compression check. If you had all 4 plugs out while doing the check, and your compression came out good, then the head gasket is fine. However, if the gasket is blown between 1 & 2, and you replaced the spark plug in each cylinder as you went, then that plug would hold the compression in via the blown gasket passageway.

[Agemax]

+1 clogged exhaust. There really isn't much that is common between 1 & 2.

Also, it COULD be a bad head gasket, depending on how you did your compression check. If you had all 4 plugs out while doing the check, and your compression came out good, then the head gasket is fine. However, if the gasket is blown between 1 & 2, and you replaced the spark plug in each cylinder as you went, then that plug would hold the compression in via the blown gasket passageway.

no it wont, if #1 is up on the compression stroke, #2 will be near bottom with at least 1 valve partially open, so it wont hold any compression between cylinders.

[lemonshindig]

no it wont, if #1 is up on the compression stroke, #2 will be near bottom with at least 1 valve partially open, so it wont hold any compression between cylinders.

I stand corrected.

[esmithers]

Update

Okay, i have removed the exhaust blown it out and washed it out with water to push anything that the air didnt get out.. hung out to drip dry.

While that was drip drying i checked the clearance on the shim/lash per the Suzuki Service manual from bikecliffs site. everything was within spec and ok. replace the valve cover back on and tighten everything down.

cleaned the plugs and made sure connections were connected and seated. charged the battery. while exhaust was off i looked into each cylinder and witness both intake and exhaust valves move in and out so they are performing as needed. bought new fuel line hose and vacuum hose.

all this was done i placed the exhaust back on the bike and put the fuel tank on the bike and notice it had like half gallon if that in the tank so had the tank leaning on the petcock side to ensure fuel is flowing.

turn the valve to PRI and notice a dribble but then no flow of fuel. so i placed it on RES and cranked over the bike.. didnt crank up and run. place the charger on JUMP mode and turned the bike over and the bike failed to fire up and run.. shot some ether in the intake of the breather case and it acted like it wanted to run but nothing happen.

So with all this i am taking a break, once i have calmed down and cooled off i am heading to Gas station to get some gas and place in the bike take top off the tank. once this happens i will try to crank the bike and hope it was just starving for fuel and the bowls were not all filling up. wish me luck and hope after this head ache i get some great results.

P.S. still leary of the Signal Generator (only part i have not replaced for the Ignition system.) If you or someone you know has a S/G that your willing to part ways with please let me know. I would like to get it from you. thanks.

[chuck hahn]

If theres only half gallon of gas put it on PRI or put another gallon of gas in. RES wont prime dry carbs from running them out of gas....that's why theres a PRIME setting!!!


Prime them for about 30 seconds or so and it will start.

[esmithers]

Chuck, the carbs had fuel already in them prior to removing the tank to deal with the valves. they were not dry.

any note all the carbs are filled with fuel i just checked and well seems somewhere have missed a connection or something came loose. damn bike wont fire up. so back to square one. figure out why the plugs are not firing..

So now i have to remove the tank and check all my connections once more and get the old trusty multimeter out and check connections.

[tom203]

Not firing now (but was before you said)- check the 4 pole connector plug (under seat on right side) that connects ignition coils to ignitor. One wire feeds 12 volt positive to ignitor.

[chuck hahn]

What he needs is a close member to go and lay eyes on whatever has been rearranged etc etc.

He once had a nice spark and now he doesn't.

The carbs are as clean as they will ever be.

He said he has new coils and wires and caps.

The carbs are getting fuel.

Exhaust isn't plugged.

Said he saw the valves moving so they arent stuck.

Said he had numbers well over 100s for PSI on all 4 cylinders.

Said he has all the valves within spec.

Said he replaced the ignitor with an Ebay one that the seller said was good and showed him a video of the supposedly running bike it came off of...but was it really a good ignitor??? Who knows.

He has eliminated all the mechanical stuff so its gotta be electrical somewhere I would think. Corroded connections, broke wire somewhere, bad ignition part..something other than valves and the carbs

[esmithers]

i am getting 11.5 volts to the coils via Coil relay Mod.

from all that is check i believe my signal generator is not correctly functioning.

the no spark from earlier today must have been too bright to see the arching plugs, but now that we have dark clouds above i am able to see the coils are firing on all four.

Tomorow i am going to get some ether and new plugs for the bike, and see if possibly the plugs went bad. who knows at this point. any suggestions outside of what has been established is greatly welcomed.

Chuck, thanks for the idea of the plugged exhaust, that help ensure one thing that i would have not even thought about checking.

Additionally. with the exhaust off i seen no major defects to the tubing that would allow inadequate back pressure. they were all rusty but very solid and were good enough to bring the bike to stock.

Tom, as mentioned, the plugs are firing and i have the relay Mod in place to have constant voltage to the coils.

thanks everyone for your ideas and suggestions.