Bike has lots of niggles any help appreciated

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Hey guys, I used to be a member on here some time ago until I had a Big off back in 2012 on my R6. Not been back on a bike since mostly out of respect to wife and kids as they didn’t want me to. Anyway traffics my way has been horrendous for the last 18 months with multiple road closures and therefore managed to convince the wife I needed another bike. Budget was low however I managed to pick up a Honda 600 Hornet on a 01. Bike has far more miles then I would have liked but it was a quick purchase and as I say budget was low.
So the bike has a few issues, firstly the exhaust is leaking from where the headers meet the block. I don’t want to pull it apart just yet as I need it for work over the next couple of days but can I confirm will there be studs on the block that the header bolts onto or will it be boots that screw into the block? Other then the bike sounding a bit noisier will it cause any issues whilst riding it over the next day or so?

From there I have some electrical problems which are
1 Rev counter works fine until you switch the lights on and then it stops working. Lights off and it starts again.

2 no back light to the dial cluster

3 the head light has been changed for a twin set up and appears to have been wired up wrong and when the switch is on full beam the lights appear to be on dipped.

Rectifying these issues would be a great start and I appreciate any advise

1198 · World Chat Champion Joined: 24 Jan 2013 Karma :

Point three - do you have a dvm and a wiring diagram? Open the lights and check if the right coloured wire if being energised when you operate the high beam? That’d be my start point.

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Yes I do have a volt meter and I have found a wiring diagram online not sure if it’s the right one though.
The headlights look to be dominator headlights

BusterGonads · Trackday Trickster Joined: 18 May 2018 Karma :

Re reversed dip/mainbeam. Certainly the wrong wire may be connected, but if the previous owner has had the bulb socket off the harness, it is possible to reassemble it the wrong way around. I know this because I did it. I solved the issue by plugging the bullet connectors for main and dip into the wrong receptacles. Dirty, I know, but easier than reassembling the holder properly.

Speedo cluster backlight not working - possibly a loose wire, maybe more likely a failed bulb . Just bought twenty of those wee things for about £2.50 on ebay.

Of course, if the electrics have been modified by an idiot, anything could have been messed with.
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2023 Royal Enfield Classic 350; 2000 Honda CG125; 1997 Honda Nighthawk CB250

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Well just quickly pulled the headlights apart and swapped the main and dipped wires over and guess what.... still the same! When on dipper the light beam is higher when on full beam (blue light on the dials is on) the light beam points lower

Polarbear · Super Spammer Joined: 24 Feb 2007 Karma :

Nobby the Bastard · Harley Gaydar Joined: 16 Aug 2013 Karma :

Your headlights have been fitted upside down and there is no earth to your instrument cluster.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

Polarbear · Super Spammer Joined: 24 Feb 2007 Karma :

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Polarbear · Super Spammer Joined: 24 Feb 2007 Karma :

Nobby the Bastard · Harley Gaydar Joined: 16 Aug 2013 Karma :

The lens may be fitted to the headlight correctly but the headlight itself may be upside down.
____________________
trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

So the dramas didn’t finish, set off for work and all going fine, start filtering through traffic and as I come to a stop the engine cuts out and wouldn’t re start and sounded like a flat battery. Tried bump starting wouldn’t have it and so called the RAC. RAC turn up and jump start the bike, puts multi meter on it and it shows as charging albeit charge rate was a little low. Ow maybe coincidence but I had only switched lights on a couple of minutes before as a i came to the back of a long que of traffic.
I’m wondering could my rectifier be at fault or could this be a drain from the lights causing it

Rode fine the rest of the way to work. This evening wen to start and took a few attempts. Rode home doing 70 on motorway and suddenly realised it was no increasing speed, turn throttle to full position and didn’t accelerate. A mile or so late it started slowing to a point I had to pull onto the hardshould and it continue going at around 20mph, it the. All of a sudden kicked back into lift and carried on the rest of the journey.
Now could the blow I have in the header be causing a mess with the fuel mixture causing it to over fuel and bog down or soot up the spark plug or could this be a blocked fuel filter which then cleared.

Sorry for all these questions

colink98 · Could Be A Chat Bot Joined: 27 Jun 2016 Karma :

P. · Red Rocket Joined: 14 Feb 2008 Karma :

As above, I'm closer to Dartford/Bluewater area if you wanted someone to have a look over it.

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Cheers Paddy and Colin, I’m going to have a look at it today and if I have no success will take you up on your offers. I’m in Folkestone

colink98 · Could Be A Chat Bot Joined: 27 Jun 2016 Karma :

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

So a bit of an update. Pulled the instrument panel off today and headlights. All the earths coming from the back of the panel were a mess, some were just twisted together. Pulled them all apart and soldered. Result is i now have an illuminated cluster and working rev counter when lights are on.
Head light wise, I have a swap around of the wires again and again an earth issues. These ar now working correctly Very Happy

Pulled the reg/rectifier off and made sure all terminals were clean.
Went to start her and she was dead, battery flat again but as the engine hadn’t been running all morning and the ignition and lights had been repeatedly on and off I can only put it down to that. Put the battery on charge and a few hours later tried again, she struggled to start but sounded more of a fuel issue as it wouldn’t fire. Soon realised that where I had removed the tank earlier in the day that the smaller of the fuel pipes had got kinked upon reinstall. Also I had put it on reserve. How ever once this was sorted she fired into life.

So now it’s just the down pipes and the blow at where they meet the block. Don’t trust myself to remove it without snapping the bolts/studs so popped down local bike shop, they said worst case scenario would be half a days labour.

Pothole · Two Stroke Sniffer Joined: 18 Aug 2019 Karma :

Threw some gloop around where the manifold meets the engine today, let it set and fired up, definitely a lot quieter from the front end and less tappy in sound. It will do for the next couple of weeks. I have ordered Delkevic stainless headers and will get the garage to fit them as I can’t be doing with snapping any studs