xristos said:
NSman: the engines just had a full rebuild but like i said everything has been checked and rechecked and all is ok but for the timing of the spark i think.
Scrapview, so what did you do to resolve the problem of firing when the valves were on overlap? . I've tried 3 different new plugs all with the same result so ruled that out. Thanks for the tip, tomorrow i'll see when it blows my thumb off relative to spark firing
Xristos,
The plug fires on overlap, or the top of the exhaust stroke every time, what scrapeview is telling you is the under compression there is not enough voltage to jump the gap, and that this can be caused by a bad spark plug. Remember, the plug fires everytime the piston is at TDC, not matter if it's on compression or exhaust.
Second, are you sure that the part numbers are the same for the CDI's? I checked my parts book for the 04 and the 450 CDI part # is 800.39.031.000 and the CDI part # for the 650 is 800.39.031.200. And since it pops and flames on the 650, but nothing on your 450, I would say this kind of confirms this.
Here is some other possible electrical problems: #1 The plug cap is bad, un screw the plug cap from the coil wire and use and ohm meter and read through the plug cap from top to bottom. If your ohm meter is not an auto ranging meter, set the range to measure up to at least 10Kilo ohms, your plug should read right around 5Kilo ohms. #2 Disconnect the kill switch where it connects to the coil and isolate/insulate that wire coming from the coil and try and start it, if the plug cap checked out okay.
Next, you haven't told us if you were using the choke or not when trying to start it. It could be that the carb is plugged up and may need a thorough cleaning.
And you are correct, there is no adjusting the timing on the Kokusan ignition bikes. Unless the following is true, as it will have a direct effect on timing.
The worst case scenario is that the cam was not timed correctly when the motor was re assembled. The only way to know for sure is to set the motor on TDC on what you think is the compression stroke, insert the engine locking bolt in the front of the engine pull the rocker box, and then look at the cam wheel from the left side of the motor, you should see two dots on the cam wheel close to the chain, one in the front and one in the rear. They should be even with the top of the head, and the cam lobes should be facing down towards the head. If this is not the case you will have to remove the cam chain tensioner, split the chain, time the cam correctly, and then re assemble the cam chain. The 04 repair manual is free to down load from the Husaberg.se site and has step by step directions and pictures.
The only other thing I can think of is that the valves have been adjusted on TDC of the exhaust stroke, or overlap.
Hope this helps,
Dale
