It looks like I'm finished.

[cywelchjr]

It's Alive!

I know you said you checked this, but try switching the wires to the coils. It is pretty simple and may solve our problem. I've seen this be the issue after switching out the pickup coils on more than one occasion.

I'm stoked! I checked the wires, and the colors matched, but I swapped them anyways, and it started right up on the first try. I've got a ticking noise that sounds like it's coming from the valves , but it's idling smoothly and revs quickly, and I haven't even set the timing yet. The only issue at this time (other than I'm sure I need to adjust the valves, which I'll measure during the week and hopefully get the right shims next saturday), is that the clutch is not releasing. I'm pretty sure it's assembled correctly, and I think I finally have it adjusted right (took 3 tries to get the feel for it), but I can't stop the rear wheel in gear without killing the engine. It also won't start in gear with the rear brake applied. I'll pull the side cover off again if I need to, but I'm hoping it's just stuck and that I'll be able to get it freed up. If not I may need to get some clutch parts once I figure out what's wrong. But it runs now.

[cywelchjr]

So if the replacement motor has no compression of a couple cylinders, what are the chances that it had some bent valves when sent to you? That is what the symptoms say to me, but I am by no means an expert in this. Did you adjust the cam chain prior to firing the bike up? If it is just bent valves, couldn't you take the valves from the old motor? Then, all you would need is a valve cover gasket or some yamabond/rtv. Things might not be as bad as they appear.

Well, now that I switched the primary coil wires, it's idling smoothly and mostly quietly (I'm not sure if the ticking I'm hearing is an exhaust leak or valve noise). I'm going to check the exhaust, and I may put new exhaust gaskets in since I used the ones that came with the engine, and if I have a leak it's on one header, which maybe it's a bit loose?

[XJOK2PLAY]

Cy,

Hang in there & keep battling it! You're too close to give up now!

Glad to hear you got it going.

Bob

[rpgoerlich]

Just be careful torquing the exhaust nuts down. You dont want to snap off a stud...
You might want to remove the nuts first, clean up the stud, lube them then re-torque.

[cywelchjr]

Just be careful torquing the exhaust nuts down. You dont want to snap off a stud...
You might want to remove the nuts first, clean up the stud, lube them then re-torque.

I haven't actually torqued them yet, just brought them up to what I thought was decently tight, but I'm going to get the right attachment and use my torque wrench and put them at proper torque and see what happens. I did make sure everything was clean and such, so they may just need to be properly torqued.

[DGXSER]

Glad it worked for you!! The valves in these beast are louder than alot of other machines, but an exhaust leak is quite possible also.

Good luck with it! Your out of the woods at least!!

[tarzan]

If that motor hasn't run in a while the clutch plates can stick together.
Before taking it apart,I would run it till it's good and warm and then ride it around a bit and give it throttle and let off quickly.You may be able to break the clutch loose.It's worth a shot anyway. I've had this happen on a couple different bikes.