Re: job done it starts but......

ROWLEY · Jul 5, 2004

.......it won't idle!

In order to solve the decomp shaft oil leak, I've taken off the battery, s/motor, trans cover etc to put an O ring on the kickstart decomp shaft (inside). This involved removal of the clutch and kickstart assembly etc. It's all back together now.

It starts first or second kick but won't idle, and there's fuel appearing in the rubber carb boot

Have dismantled and cleaned the carb again, checked the timing, changed the plug - I'd done the valves around 2 hours ago (street use only). There is a spark that seems bluish, and all carb jets are standard.

The engine started and ran perfectly before the O ring job - but oil loss was big Upon kicking over with the air filter off I can see that fuel appears to be blowing back into the carb boot

It appears from B's reply to this message left in 'Fuel' earlier, that I probably have not lined the clutch and various other cogs up - so I've messed up the timing

Can anyone please advise how I can remedy the situation? I have no info otherwise :?

Please, please provide help asap you clever lot

Best regards

Rowley

Simon · Jul 5, 2004

Someone somewhere had posted a scan of the timing diagram - can't remember who, so can't provide a link.

However, what you need to do is:

1 set engine at top dead center on the compression stroke
2 take off the clutch casing again
3 Look at the 2 gears to the front of and with their gears meshed with the clutch basket. The bottom is the crank, the top one is the cam chain/balancer shaft
4 on the crank gear you should see 2 dots embossed, and on the balancer shaft gear there is 1
5 the gears should be lined up so that the single dot of the balancer shaft gear lines up between the 2 dots of the crank gear.
6 If not, take apart and re-align

HTH
Simon

Taffy · Jul 5, 2004

try this here

Taffy

ROWLEY · Jul 5, 2004

To Simon

Thanks for the info.

So if they do not line up - how do I rectify things?

Sorry to be such a ****, but I really want to get this right - I've had the trans cover off so many times I'm losing enthusiasm now

Many many thanks

Rowley

ps Taff the link went no where :?

Taffy · Jul 5, 2004

try again rowley, i left a dot out.

Taffy

Simon · Jul 5, 2004

Re: To Simon

ROWLEY said:
Thanks for the info.

So if they do not line up - how do I rectify things?

All you need to do while keeping the engine at top dead center, remove the clutch basket and twirl the balance shaft gear until they dots line up.

There may be some minor twiddling and adjustment of the crank/balance shaft while reassambling the clutch basket again, but no more than a degree or so in order to line the things up.

Now, just a word of advice - next time you remove things from the engine, just have a good look round to see what the layout is, even use a marker pen to remind yourself - even take a digital photo of the way it looked before you take things apart - it really helps when putting it back together :wink: :wink: :wink:

We've all done it and hopefully we all learn :wink: :wink: :wink:

HTH
Simon

ROWLEY · Jul 5, 2004

To Simon & Taff

Great stuff guys

Many many thanks again!!!!

Rowley

ROWLEY · Jul 5, 2004

One Last Thing (please)

Alex from Dave Clarke Motorcycles told me I can somehow lock the piston at TDC - something at the front of the engine?

Is that right?

Compared to you guys I am but a worthless worm:?

Regards

Rowley

hribman · Jul 5, 2004

Hi Rowley,

yes thats right. The 2003 models has got a thread in front of the crankcase. There you can lock your crankshaft with a screw.
Older models donÃ‚Â´t have this thread hole.

greetings

hribman

ROWLEY · Jul 5, 2004

To hribman

........so our 02's don't then. Never mind.

Many thanks

Rowley

Taffy · Jul 6, 2004

rowley

i've just had a rotten time getting the valve timing right on mine and that's after years of experience at other make. every bike is different-right?

so if you want to be sure the cam timing is right then first of all i would pull the sidecover off, the ignition cover off and the rocker box off.

on the ignition side, use the top bolt hole as a marker. the long line on the flywheel is at 10d btdc, the short line is at 5d btdc so one more imaginary line-equadistant-and you're at TDC.

now look at your cam lobes. if your one cycle out-turn the engine. get the lobes to the top and then they must be parallel with the top of the cylinder head. this is with the tensioner in and working. absolutely parallell.

if you are out it'll be that gear in the clutch cover. whilst simon is right i would add that the gear above the crank gear becomes detached from the clutch gear first. so just pull everything far enough forward so as to modify and turn that gear.

can you download the diagram now?

regards

Taffy

ROWLEY · Jul 7, 2004

To Taffy

Great stuff Taffy. Yes, thanks I've got the diagram now - brilliant

I'll take of the trans cover, mark a third line for TDC at the ign, then check everything. It won't be put back together unless I'm sure - I'd rather runs things past you guys first :?

I hope to do things this weekend but may not be until next. The weather looks sh*te anyway eh?!

Thanks again

Rowley

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