Dellorto 38 CD1 jet - FE600 -94

My 94 600 is hard to start so I thought I should try and install a CD1 jet inside the pilot since my bike didn't have this.

If you have the CD1 jet inside the pilot jet, how far in should it go? All the way until it seats?

My bike is kickstart only.

Thank you.

OK. So now the bike starts quite easy when it's cold.

1. idle screw out one turn
2. fuel screw out two turns
3. choke on
4. kick it from compression stroke (where the kick lever wont move without decomp) two-three times until I get an exhaust boom.
5. kick it from TDC (exhaust valves closed/intake just about to open) starts on one kick.

When fiddling with the idle and fuel screws after this I got a few exhaust bangs while running, especially if I revved it up and let got of the throttle. When engine is stopped it can't be started again until cold (procedure 1-5 again).

Any ideas?

I don't have any smaller pilot jets around so I'll try to drop the needle an disconnect the oil vent. I really haven't used the bike alot so I don't know about oil consumption. But the compression rings, oil rings, piston and cylinder were all way within spec.

Pilot is 52, needle K32, emulsion tube AB265, choke jet 45 and main jet 180, round slide no 50.

I'll checkk if the emulsion tube hole is oval.

The cam timing is set with the flywheel TDC mark against the bolt hole mark in the cover. I have confirmed with an indicator dial that this is true TDC. The cam is then set with the cam sproket bolt holes at three and nine which put the lobes in eleven and one position. Cam chain stretched on the pull side. When I pull the engine around it comes back to the same position.

But when I fit the rocker cover and let the engine come to natural rest in TDC with the lobes pointing up, exhaust valves about o close, intake valves about to open, the rotor TDC mark is actually like five mm left of the mark in the cover.

Should I try retarding the cam one tooth? Would this possibly explain the exhaust booms and the flames out of the muffler when I rev it and let go of the throttle? Would this cause hard cold starting and impossible to start when hot?

Should be fine on the cam timing then. I'm just grabbing after anything right now, hard to start, impossible when hot. Lots of exhaust boom when letting off the throttle after revving it. But it sedm to respond well on throttle when revving up.

Valve clearances are done at TDC with the lobes facing down (rockers relaxed). I get a 0.1 feeler in easy and I can pry in a 0.15 so that should be ok.

Question on gaskets: how am I supposed to seal between the head and the exhaust pipes? The parts manual shows no gasket here. The same for the pipes to the muffler connection.

Second question specific for Taffy: Does your head gasket require a higher cylinder/head bolt torque? The fire ring seem to be a bit harder than on the one that was on my bike before. I have torqued to 44 Nm but have a tiny coolant leak at the head gasket. It also seems like the water finds it way to the cam chain channel and the oil goes milkshake but the level drop in the radiator is not noticable, I can only see a drop on the floor once in a while.

OK, Now I'm totally sure it's fuel related. Everything else is double, triple, quadrouple checked.

Piston within spec measured with micrometer. Rings within spec, measured with feeler gauge in cylinder. Cylinder wall looks like new and within spec, measured with bore dial. Compression is good, it's not possible to kick around without decomp. New exhaust valves lapped in and fluid tested. Old intake valves lapped in and fluid tested. Valve clearences set to 0,1 mm at TDC with rockers relaxed (lobes down).

New cam chain. Cam timing set, lobes pointing up at TDC perfect aligned with TDC mark on flywheel. TDC mark checked with dial thru spark plug hole.

Timing set with pin thru flywheel in to stator. Aligned with flywheel mark 34 mm ahead of tdc (33-34 degrees advance).

New coil (previous owner). New spark plug CR8EIX Iridium. Strong spark even at low speed kicking.

Carburetor. All jets inspected and clean. No ovality in needle jet. Have tried with and without CD1 jet (didn't have it from start), lean popping/flames out the exhaust on deceleration with CD1 installed, none og this without CD1. Floats and float height OK. Idle screw one turn out from bottom (idles high when it starts). Fuel screw two turns out from bottom (seem to be smoothest idle when it starts and choke is off. New intake rubber, no leaks.

Bike is still hard to start. I have found a method that work when the engine is cold and with choke. When the engine is warm it doesn't ignite at all when kicking. If I don't turn it off it will run good with no misfires when warm so I don't think it's got anything to do with overheated coil or stator.