spluttery pop pop

[dandywarhol]

You're right.

[davamb]

Sounds exactly like my issue PWM. Only played up in the wet. Does the tacho needle bounce around a lot? Have you tried adding a lead from battery to frame? The way the bike's wired is only with a lead from battery to engine and seems like it relies on engine to frame bolts to make the connection back - not too clever if you ask me. There's no reason for you to ever get a belt off the bike - somewhere there's a spark not able to get to ground!

[Mincehead]

To get a shock it`ll be HIGH TENSION too, output to the plug leads or from the `body` of the coil with likely the insulation breaking down.
I would first replace the leads, then if there`s no improvement the coils themselves!

[davamb]

Still got a couple of splutters tonight. Needs more investigation. Have looked at TRX and TDM wiring diagrams and honestly can't see how the condition of the starter solenoid would make any difference to how the bike runs. How the starter motor runs yeah sure, but the ignition???

You getting a belt off the bike is either a lack of a ground path in the ignition circuit or a breakdown in the HT section PWM.

[trixynut]

Mate, no bright ideas sorry, but still got a complete loom here if you're interested, minus reg/rec, coils, condenser etc though.

Should be reasonably easy to lay it on the bike, connect up where needed and if it cures the problem, fit it on properly.

[phuk72]

Mate, no bright ideas sorry, but still got a complete loom here if you're interested, minus reg/rec, coils, condenser etc though.

Should be reasonably easy to lay it on the bike, connect up where needed and if it cures the problem, fit it on properly.

Once you've stripped the bike down, changing the wiring loom is pretty straight forward

[davamb]

Got some investigation time in this evening so went out to feed the mosquitoes. Battery voltage around 11.5 at idle with lights, grip heaters and indicators on - not real flash, maybe time for a new battery. Picks up to around 14v at around 2k rpm, so charging circuit is ok.

Next the earthing theory I'm investigating. Haynes circuit shows a ground or chassis connection out of the rect/reg but it just seems to plunge into the loom and head towards the front of the bike. Must trace this out. Diagram also shows chassis for each coil, seems to be done by the core. There is a ground connection on the RHS coil. Don't know where that goes, seems pretty low current. Removed, cleaned and replaced connector.

There is a couple of mods, extra wires and non-original looming. Pretty sure the rev limiter's been bypassed and there's over-ride switching for the fan and lights. Quality of work seems pretty average. Hmm... fan override - interesting.

Will continue looking into this. Not stopping 'till I get to the bottom of it!

[Mincehead]

There`s an Earth back to the frame up around the thermostat region if I remember correctly Dave, that from memory comes out of the loom.

[davamb]

Thanks Mince, I'll trace that down and check out goodness of contact.
Went back out late last night and had another look over, of all things the battery negative connection was just a little loose, but should still have made good contact. Still - remove all the known problems first!
And she ran fine this morning on the way to work (30 mins of highway ride). Gonna rain this arvo so will see what happens in the wet - if anything changes.

[davamb]

Damnit! Lotsa k's on the rex, even some in the rain, and it hasn't cracked the shits again. Hate intermittent faults.

Going to have to do something about the zorsts though, they are way too loud. Begging to be hassled by the next cop that I pull up alongside. Think the fibreglass has been slowly burned off or blown out. Sure it never used to be that loud!

[trixynut]

CBA to read back through all this stuff, but has it been suggested you check the sidestand cut-off switch? Prone to water shorting it.

Soz if its been covered.

[davamb]

Might have been mentioned before. It's difficult to read your posts Trixynut, your avatar's rather distracting...

sorry... what are we talking about?

Orright. Yeah it's a possibility. Doesn't agree with the symptoms, but it won't hurt to investigate. Will be repacking the mufflers tomorrow, will have a look then and report.

[zednine]

http://www.carpe-tdm.net/ipb/index.php? ... 8&hl=relay

http://www.carpe-tdm.net/ipb/index.php?showtopic=9178

[davamb]

Thanks ZedNine. Have checked the starter solenoid - all good there, will have a good look over the HT leads!

[davamb]

Went over the sidestand during the weekend, took off the whole thing cleaned it all up. Took apart the switch itself, all in perfect order (you can pull the case off the switch to expose the contacts but make sure you don't drop any of the pieces!!!!). Re-assembled it all. I'll have a good look over the ignition leads next.

Also made up a bit of a baffle restrictor to quieten the old beast down for the big tour I've got coming up, worked ok noise wise, but already starting to blow the 'glass out. Will redesign over the next couple of nights.