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Post by ArturHawk on Oct 22, 2020 15:31:05 GMT -6
Ok, I'm stumped and need some help. Please excuse the long post but i'm gonna try to add a little before it wont start for background.
1989 kawasaki 454 ~5k miles was running great.
I started to get a rattle between 4.8k and 5.5k rpm. For the next couple days I was trying to figure out what was making the noise. I looked at the wind shield, electrical connectors, etc. Basically anything that had any ability to move.
I rode the bike to work and when I stopped, I put my kickstand down before going into neutral and the bike turned off. I'm still a new rider, so thank goodness for safety switches! I put the bike in neutral and went into work.
When I went to leave, I mounted the bike, turned the key to the on position, moved the kill switch to run and there was a "pop" and my carburetors moved and I saw a little puff of smoke come from the right side of the bike. I did not touch the starter button to make this happen.
Now the bike cranks, but won't start. 🤔 I hooked up a timing light to both plugs and i'm getting spark. When I used the timing light on cylinder 1, I aimed it at the crankshaft and it seemed to like up every time the "F" mark passed the window. I'm guessing "F" is for Fire?Cylinder 2 didn't flash in relation to any timing mark that I could see. I tried starter fluid in the air box. I even tore the top of the engine down to make sure I had all my adjustment nuts tight when I did a valve adjustment. Good news is valves are perfectly adjusted at the top of the range right where I left them.
Any ideas on what is wrong or where to go next? I'm just stumped because the bike was running like a champ in the morning and dead in the evening.
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Post by ArturHawk on Oct 25, 2020 20:18:20 GMT -6
Figured it out!
The carbs moved backward toward the air box so they no longer had a good seal with the engine. I moved them forward until the rubber coupling was against the stop tab on the carbs and the bike started! It only took me 8+ hours to figure it out. Easy!
Unfortunately, I cranked the bike so many times trying different things, I think the starter clutch is dying. It sounds like the starter is skipping every once in a while.
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Post by knoizy on Oct 26, 2020 8:08:45 GMT -6
Success! A hair drier on the carbs rubbers will soften them up nicely, some folks have made a tin/jam jar lid with cord to pull them back smoothly for removal. The starter clutch can fail due to worn springs, rollers or hairline cracks in the body, once the generator cover is off you can probably see if its slipping. Easy job but quickly turns difficult without a flywheel puller, strap wrench and the hex bolts holding the clutch to the flywheel might be threadlocked needing a bit of heat to release.
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