CBR 125 RW9 not starting

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

so i have a cbr 125 rw9 FI model, after the old carbon steel exhaust blowing i decided to change it, loan behold part of the header pipe was stuck in the cylinder head. the only way to get it out was to take the engine off or risk hitting other components. long story short. after taking the engine off and putting it back together the right way (i have a logical mind) so everything is where it should be and all good. however the bike refuses to start, it will spark but only ever turns over on the starter motor it will not fully fire.

this is what i have tried so far....

tappet clearance to service manual spec Intake - 0.06mm +- 0.002mm Exhaust - 0.27 +-0.011mm
new tank of fuel after being flushed to get rid of anything old.
new copper core spark plug
fuses have been checked and all OK
injectors have been cleaned and seem to be sending fuel (plug gets wet)
spark plug is sparking with a (blue) spark against the frame.
new HT lead only fitted 2 months ago.
breather and vacuum pipes are all ok none kinked or broken.
new oil to the required mark on the dip stick.

im at a total loss! and its frustrating the hell out of me Sad

the bike started and ran fine before it was removed form the bike, but after it was all put back in the same way it refuses now.....

any troubleshooting or guidance would be great and thanks in advance

spottedtango · Trackday Trickster Joined: 04 Dec 2015 Karma :

An engine needs 3 things to run. Compression, spark and fuel.

You're saying you're getting a spark and fuel as the plugs are wet. That would only leave compression.

Have you checked the compression and valve timing as it's very easy to get timing a tooth out?

If compression is okay then you need to double check the injectors or ignition system

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

when doing the timing i have it to the T mark on the crank and then my partner was holing it in place so it would not move. (more steady hands than me!) done the timing to almost spot on perfect.

there is LOTS of compression as it will blow your finger away when the plug is out.

the injector unit was removed and all cleaned out best i could. still nada...

Jmh600 · Nova Slayer Joined: 02 Mar 2016 Karma :

Almost spot on, and actually spot on are two different things. If it's not timed correctly you can cause a serious shit storm inside your engine.
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Jmhmotorcycles

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

lets go for spot on lol the feeler gauges moved freely but with a little resistance not overly tight and not overly free. checked almost 5 times after manual rotation of the engine via the inspection ports turning the 17mm bolt inside

Jmh600 · Nova Slayer Joined: 02 Mar 2016 Karma :

You're on about valve clearances. Not timing. But a haynes manual for your bike and try again.
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Jmhmotorcycles

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

i have a hanyes manual already, followed the steps in the book, thats where i got all my measurements from

spottedtango · Trackday Trickster Joined: 04 Dec 2015 Karma :

It sounds as if compression is okay but there's something being over looked.

If the bike was running before then its unlikely there's going to be anything major wrong.

I'm assuming you can hear fuel pump priming when you turn the key. You've made sure that the fuel hose is firmly clipped into the tank/fuel pump as they can take a bit of a push to get on.

A dodgy injector can be tested by unclipping the wires from the injector and measuring the resistance between the two pins. This can be compared with a values from a workshop/haynes manual. It's unlikely to be this though

When you say taken the engine off you're meaning the cylinder head off or the entire engine out the frame?

Id check earth's and just have a general look about the electrics to see everything's where it should be. Neutral/ oil pump wires, side stand switch.

I'm willing to bet its something electrical.

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

@spottedtango.

yes full engine out, the frame was looking shabby so i thought might as well clean and paint it at the same time. im in two minds myself its is an electrical issue. i cant see any fuses bust but there is 1 fuse that i cannot see! its a 30 amp fuse. i have a spare in my battery bay so must have 1 on the bike somewhere, ive been looking through my manual but cannot find it anywhere Sad

losing the will to live at this point lol

spottedtango · Trackday Trickster Joined: 04 Dec 2015 Karma :

I meant to add, you've made sure the (MAP/MAF) airflow sensors along with (TPS) throttle position sensor, if its a fly by wire type have all been reattached and clipped in properly.

spottedtango · Trackday Trickster Joined: 04 Dec 2015 Karma :

Its something daft honestly. Go have a cup of tea and come back to it Laughing

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

lol i will ponder at it at work tomorrow, it's cable throttle system, all the cables are attached where they should be so i will have another bash at at and see what it brings to light.

davidnumeral · L Plate Warrior Joined: 02 May 2016 Karma :

so...after looking at the bike a little further i found that the rubber intake sleeve that goes from the injector unit to the cylinder head was misaligned, however the bike will still not go after this was pushed back to where it should be. i also checked the injector electrics and all seems to be in order. i though maybe the injector EMU might have been at fault but after testing the electronics all seems well also.

any other theories?