GS500 splutter. Again.

_Iain_ · Banned Joined: 01 Feb 2012 Karma :

2/3 or more throttle/over 5500rpm, splutters & boggs like fook.

Last time it was carb rubbers that caused this. New engine came with very good carb rubbers, that i've taken off, cleaned & resealed with loctite copper sealant. Which specificly says its reccomended for inlet manifolds on it.

https://i1148.photobucket.com/albums/o574/_Iain_/3208AD56-AC67-4DF6-B7A3-544BCEDDE7FE-209-0000000E611B5C53_zps8a1273f0.jpg

Loctite on as above, wiped the excess that squished out on the inside. 100% sure of no leakage.

Airbox rubbers are again good. Fuel tap isnt the cause of problem, as bypassed this and ran straight from reserve line to carb. Splutter still there.

Removed & stripped carbs and found this shite.

https://i1148.photobucket.com/albums/o574/_Iain_/3220AA24-03FC-49AB-8E69-FFF7C1DA19BC-209-0000000E69F87380_zps658035de.jpg

https://i1148.photobucket.com/albums/o574/_Iain_/C579AE30-307C-415F-8630-1A297B89DA0B-209-0000000E6EF5284D_zpsf3e14e42.jpg

https://i1148.photobucket.com/albums/o574/_Iain_/C2F5B163-5B4E-450A-AE52-D45F6C59B4FC-209-0000000E763B946E_zpsbda6cb6e.jpg

Cleaned with carb cleaner, removed jets & checked for blockages. Nothing. Cleaned inlet of carbs with carb cleaner.

https://i1148.photobucket.com/albums/o574/_Iain_/05FE0EAD-40FC-43CF-98F2-5E901EAB2FE7-209-0000000E7F7E6747_zpse7df7965.jpg

Squeaky clean.

Occasionally the fuel filter runs with next to no fuel visible.

Plug chop shows running VERY lean. As expected. So what have i missed, where do i need to look next?? Mad

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orac · World Chat Champion Joined: 25 Sep 2011 Karma :

looks like youe tank is full of crap, drain the the tank and remove the crap, maybe see if you can seal it up (that what i did with the rust in my tank). why is nobody ever expects it to tbe the tank itself
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"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

Well, it's getting there either via the fuel line or the air intake.

Looks like fuel crud, but how's your air filter? Not disintegrating? No crud coming up the crankcase breather into the airbox and getting past the filter?

Sorry for the obvious question, but are you planning to sell it as soon as you get it running, and if not, why not? For a cheap bike, it seems to be costing you a lot. Sad

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_Iain_ · Banned Joined: 01 Feb 2012 Karma :

Tanks fine, tank filters clear, inline fuel filters clear.

Some shites got in there whilst i was awaiting a new engine i'm sure of it. Stripped carbs, removed a tiny bit more of whatever that stuff was from behind the float seat.

Took it out, spluttered a bit, ran on one cylinder, completely cut out. Refused to restart, pissed about with it for five minuites, shook the fuel tap around & it realy slowly filled the filter up again.

I'm thinking sticky floats/incorrectly set floats. No whoosh sound when i opened the tank so cant be breather related.
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ZaphodBeeble · World Chat Champion Joined: 10 Feb 2004 Karma :

That bike is a pain in the ass. Laughing

Have you stuck those bigger jets in yet?
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_Iain_ · Banned Joined: 01 Feb 2012 Karma :

I have, im beginning to wonder if that's whats causing half the issue. I may put the stockers back in and see if that solves anything.

Have solved the running on one and cutting out issue by refilling the tank... Embarassed

However the carbs are clean as you like. The floats are now set correctly. The fuel lines are all clear, as is the tank tap.
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Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

Hasn't Madam Pikey from down the road set fire to it yet? It might be a blessing in disguise.
____________________
Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

_Iain_ · Banned Joined: 01 Feb 2012 Karma :

Scotsman37 · World Chat Champion Joined: 17 Aug 2004 Karma :

Could be a sticking float if after cleaning jets thoroughly?

Get some fine wet/dry sand paper roll it it tightly and twist it several times where the float valve slides in/out, and finish off with some carb cleaner. Sometimes a build up occurs there and it's just enough to make it stick and not allow further fuel into the carb or very little.

Install an inline fuel filter just in case, but I've cleaned carbs sometimes spraying it with just a can isn't enough that's why using air gun type instead is better making sure it pushes it all out from the carbs with no where to hide!

_Iain_ · Banned Joined: 01 Feb 2012 Karma :

Put factory jets back in it, sweet as a nut. F*Cking bike makes no sense. However its working so i'm not touching it till it breaks again.

Zaphod - a freinds offered me a pair of pod filters in exchange for some spares i have. Would you mind if i held onto the bigger jets till such times as i've experimented with the pods?
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Rogerborg · nimbA Joined: 26 Oct 2010 Karma :

ZaphodBeeble · World Chat Champion Joined: 10 Feb 2004 Karma :

orac · World Chat Champion Joined: 25 Sep 2011 Karma :

so your fannying arond with it casued issues, do you not think that maybe a hint to stop fannying around with it.

forget the pods, leave the jets alone, ride into the ground and seel it for spares.

and when you by another bike that is runner OK, leave it alone and pay someone else to do work on it. from your other thread you completely ignored any rules for tunning. and just because some one else found that a jet sized worked doesn't mean it will work for you. If you do decide to start cocking around with things 10% on the original jet size of the same make.
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Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

ZaphodBeeble · World Chat Champion Joined: 10 Feb 2004 Karma :

_Iain_ · Banned Joined: 01 Feb 2012 Karma :

Orac,

Are we now claiming that swapping jets explains all that black crud throughout the fuel system?? The bigger main may have been flooding out but that crap was probbably what caused the lean plug reading in the first place.

Also worth noting that a dynojet 142 is significantly smaller than a mikuni 142. And that the jetting guides were pulled from a GS specific forum as a base point to start from?

I refuse to pay £50p/h labour charges for some fuckwit to do work i can do myself. Especially when said fuckwit diagnosed a loose spindle nut as a knackered wheel bearing. No chance. I've worked in the trade before and thats why i dont trust anyone else to work on my bikes/cars!

The workshop section is for this specific kind of thing anyway. Would reccomend a quick wank & a coffee. You seem more stressed than normal Laughing

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orac · World Chat Champion Joined: 25 Sep 2011 Karma :

well you just said incorect jet size was causing splutter, and yes i read that its some where between 128.5 - 130, ie the wrong size. you dont seem to have hot plugged/plug chopped to check correct burning (you shold have burnt your fingers too)

if you were in the trade this shold have been an easy job rebuilding this machine. seems to have been more difficult than it should have been.

heck you didnt even know where those copper looking shavings came from in the sump, and you were in the trade? these are simple things that even the avaerage bakc yeard DIYer knows. but dont get me started on the bodged fuel feed on your machine. did it ever occour that pure gravity feed to the carbs could cause as many issue as it resolves?
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Current rides - 2016 Triumph Street Triple Rx, 1994 Suzuki Bandit 400 VM, TGB 204 Classic 125cc
"with nothing left to lose, there is everything to gain. It's not the size of the dog in the fight, it's the size of the fight in the dog"

_Iain_ · Banned Joined: 01 Feb 2012 Karma :

Incorrect jet size was, however i'd discounted the jets the first thing i'd done was plug chop that showed a very lean mixture.

it SHOULD have been an easier job, granted. However simple mistakes were made on the generator due to rushing what i was doing & loosing my rag with it trying to get to the BBQ. Hence managing to bend the starter gear.

Regarding the copper shavings, they COULD have been; valve seals, bits of cam bearing, main bearing, big end bearing, balancer shaft bearing, starter gear bearing etc etc etc. The list is a mile long, and we STILL dont know whats they're from. One cannot tell simply by looking at the shit where it came from. Given the engine had developed a mild top end rattle, then followed up with a loud bottom end rattle questions were raised to see if people thought the top end i.e head would be salavageable. Again, i see no problem in asking, It is after all a bike CHAT forum.

What pure gravity feed system are you on about? The GS500 runs a gravity feed from the factory. There were no versions produced with an electronic, or mechanical fuel pump. The fuel comes from two outlets on the tank, down into a vaccum tap, which then heads off to an inline filter & from there into the carbs. The vac line from the tap connects directly to the intake manifold on the right hand cylinder, again as per factory. I had talked with a few people about doing away with the tap if it was prone to failiure, but it never happend. I eventually flooded the old engine under testing following a row with a neighbour and forgetting to switch the tap off of prime.

Now, what the fuck is your problem all of a sudden? Neutral

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Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340