Still alive....

[eroellig]

...and kicking. Yeah, its been 3/4 of a year since I last posted.

Work just totally took over my life....until I was told "...thanks for the 19 years. The door is on the left." in February. My last day there was also my 10th wedding anniversary. It was a memorable day

Anyway, I finally took the time to replace the front brake rotors that were warped. The last conversations I had here were my discovery that the MikesXS rotors don't fit on the specials. The new rotors don't have as much offset from the bolt mounts to the rotors as the originals. MikesXS solution for the 650's is to move the caliper via a thick washer. That won't work on the special forks. So, I ended up shimming the rotors themselves. It is nice to have smooth working brakes.

Also reset my carb floats to the correct height so it doesn't run too lean anymore. Also made sure to rotate the boot clamps so that I don't have a stuck throttle again like I did last year! That is a little too exciting for my taste.

With all working again, I finally had the confidence to take a ride at speed down I90. Great fun! I was a little surprised at how much turbulence I have behind my wind screen. It can shake my head enough that small lettering on signs can be a little hard to read.

My first ride with a destination (about a 240 mile round trip) was last week when I rode out near Shullsburg WI. There is a cheese factory there run by a family who's name is very close to mine ( www.roellicheese.com). I decided it would be fun to pick up some of their cheese for a family reunion we had last weekend.

However, the 29 year old nature of this bike had to make a statement during that trip. The starter isn't engaging like it should. It almost doesn't turn the engine over at times. I was just going to take the starter wires apart and reclean (again), but then the ignition switch sparked when I turned it on (of course, while in the cheese factory parking lot while I'm the furthest from home!!) Rereading some old threads, it looks like the ignition switch comes apart without too much trouble, so I'll see if it can be cleaned up. I took most electrical connections apart and cleaned, but this is one thing I haven't touched yet.

The other minor issue is that when I'm cruising at about 70mph and twist the throttle in 5th gear, the engine will ping. I had mid grade gas in the tank. Is this normal or is something in need of adjustment?

Eric

[DiverRay]

Eric,
Sorry to hear about the job. I've been without work since last August, so I DO know what you are going through.
The ignition switch is easy. Two bolts from the underside and it will come out. When you take it apart, do so VERY carefully!! Pay attention to HOW the parts are sitting, as some things will go in 180 out! I found that sanding the plastic block that has the contacts with emery cloth on a FLAT surface works great. You should also check the wires and solder connections, as they can cause trouble at times. I use a lot of dielectric grease on re-assembly to keep water out.
The pinging may be the timing is off. If it's advanced, the engine can ping. I would also try to clean any carbon out of the engine by spraying Seafoam or Berrymans B12 into the carbs until it dies, then let it set for about 1/2 hour. Restart it and then ride hard in third gear to clean out the loose carbon.
These bikes are designed to run on regular gas, but will NOT run well on ANY gas with more that about 5% ethanol.

[eroellig]

Eric,
[...] Pay attention to HOW the parts are sitting, as some things will go in 180 out! [...]

Good tip.

I use a lot of dielectric grease on re-assembly to keep water out.

I used dielectric grease on all the other electrical connections that I had cleaned.

The pinging may be the timing is off. If it's advanced, the engine can ping. I would also try to clean any carbon out of the engine by spraying Seafoam or Berrymans B12 into the carbs until it dies, then let it set for about 1/2 hour. Restart it and then ride hard in third gear to clean out the loose carbon.
These bikes are designed to run on regular gas, but will NOT run well on ANY gas with more that about 5% ethanol.

Timing is good. I had checked it with a timing light.

I'll try the carbon cleaning thing just 'cause, but this engine has had a LOT of oils & solvants in it. Had a stuck ring or two that I fought for a while.

[petejw]

Hey Eroellig,
Sorry to hear about your job, that sux.
In relaion to the pinging, if your happy with the carb set up, (not running to lean)
and the ignition timing is correct, you should be able to prevent the pinging
by going to a colder plug BP7ES, or you could try a premium grade fuel, pinging is the worst thing for an engine.

[TopCatGr58]

Hey Eric,

SO sorry to hear about your job! If you were due retirement vestment at the 20 year mark, and letting you go before that for no other reasons isn't allowed by law as far as I know...but I don't know a lot about work rights!?

Don't forget to disconnect the battery...those wires at the key switch are HOT! OR...you could just unplug it from the harness before you work on it! Yeah, folks have found those wires to have come unsoldered!

Easy short term fix, use premium gas for trip home. Then you might want to check out your vacuum advance vacuum pot. When you roll on the throttle it's supposed to release allowing the timing to actually retard to the more powerful timing position, but if the plate isn't spinning easily, or the vac. pot piston/arm is sticking, then it could keep the timing more advanced than what it needed for that throttle/load!

Good luck getting home..safely!
T.C.

[eroellig]

Hey Eric,

SO sorry to hear about your job! If you were due retirement vestment at the 20 year mark, and letting you go before that for no other reasons isn't allowed by law as far as I know...but I don't know a lot about work rights!?

Nothing for me at the 20 year mark. The only thing was an extra week of severance per year of service which had just gone away anyhow This was definitely NOT the same "company" I joined all them years ago. Its just another corporate slug minded by the same short sighted CEO bumble bees that buzz around all corps these days....

Yeah, folks have found those wires to have come unsoldered!

Hmmm.... I'll definitely review that. Gotta be some reason for the spark I saw.

Easy short term fix, use premium gas for trip home. Then you might want to check out your vacuum advance vacuum pot. When you roll on the throttle it's supposed to release allowing the timing to actually retard to the more powerful timing position, but if the plate isn't spinning easily, or the vac. pot piston/arm is sticking, then it could keep the timing more advanced than what it needed for that throttle/load!
T.C.

Oh, I got home OK that day. I just don't pour on the coal when cruising at speed. Light throttle doesn't ping. I really gotta twist the grip to WOT to ping. Besides, I was interested to note that the small "towns" (for lack of a better term) in south west WI and north west IL only gave me 1 (one) grade of gas to "pick" from. And it wasn't premium.... (mental note - don't move there with high compression sports cars....)

When I did the major overhaul, the vacuum advance seemed to be working well. Everything there looked like it was moving easily. And I did install a new vacuum line so I don't have to worry about cracked rubber.

Now, one thing I do remember is that all my main jets are the same (forget which one it is) and that some report that their carbs came from the factory with slightly larger jets for carbs 2 & 3. Could that have any relation to my high speed, WOT pinging???

BTW: Now that I have richened my carbs, my low gas light comes on at about the 98 mile mark and I had to go to reserve at about 108 miles. Sound low or average for mileage for the specials?

I may yet think about the final drive swap, but I'm kinda enjoying being able to slap the throttle a couple of times and finding out I'm up to legal highway speeds. It's so very Un-Truck (2001 F250 diesel) like.

Eric

[XJOK2PLAY]

BTW: Now that I have richened my carbs, my low gas light comes on at about the 98 mile mark and I had to go to reserve at about 108 miles. Sound low or average for mileage for the specials?
Eric

Hi, Eric. Welcome back. Sorry to hear your work did you that way.
I totally understand. Worked 15 years for the local cable co. here, went through 5 takeovers, got worse every time they got bigger. One of the co's that took it over once was TCI. The employees figured out real quick TCI stood for "Things Change Instantly." TCI no longer exists... what's that tell ya?
I finally got sick enough of the treatment. I returned back to my family's business, where I've been now for the last 8 years.

I know on my XJ, I average around 30-32 mpg. XJ's have a larger gas tank than Specials, as do Standards. Sorry... Specials got the runt, I guess...)
My low fuel light comes on around 120 miles, and switch to reserve @ 150.
So, it sounds like you're about there - mpg wise. Had you ever clocked the fuel mileage before?

[eroellig]

[..]

So, it sounds like you're about there - mpg wise. Had you ever clocked the fuel mileage before?

Nope. At least, not seriously. I only got the carb floats to the right level recently. Now I just have a couple of holes in the exhaust pipes to fill in.... Hey, would that account for my pinging at 70+mph in 5th gear at WOT???? I suddenly seem to recall that exhaust leaks can impact fuel mixture???

Eric

[petejw]

I doubt that holes in the exhaust would cause it to ping,
could cause popping thru the exhaust on decel.
I get around 160k's before i need to swap over to reserve,
so I think your doing pretty well.
What did you set your float heights at?
If your lean in the mid range (slide Needle) could cause it to ping also.
Id try a cpl of tanks of different fuel and see if that makes any difference before mucking around to much with the carbys.

[TopCatGr58]

Hey Eric,

As I stated, the vacuum advance module is supposed to RELEASE The advance under strong/WOT type input, to retard the timing back to the more powerful less advanced timing position to take advantage of the richer fuel/air mix. Under low throttle low load the vac. adv. increases the timing much more to better handle the lean fuel/air mix. So...pining in WOT does sound like too much timing advance...and that's why I suggested you check your vac. advance mechanism, the timing plate, the plunger, etc., to make sure it moves freely and easily. Folks have reported that the adv. plunger sometimes got burrs on it, hanging it up, etc.!!

Another test, you could plug the vac. adv. tube/line, cap off the carb port and ride it that way, and see if you get any pinging under WOT!? The vac. adv. isn't that necessary for regular running, just provides for more fuel economy and smoother throttle response under cruising low load/throttle conditions!
T.C.

[Trainzz]

Anatomically speaking

I know on my XJ, I average around 30-32 mpg. XJ's have a larger gas tank than Specials, as do Standards. Sorry... Specials got the runt, I guess...)

That is so there is room for the insanely enlarged manliness of the rider.

[DenyP]

I understand the job thing - I am there as well. My job was eliminated February.
I agree with TC. I would first suspect the vacume advance.

Deny

[XJOK2PLAY]

That is so there is room for the insanely enlarged manliness of the rider.

Lee, I was TRYING to be nice...

And by the way, how would YOU know??? LOL

[eroellig]

Hey Eric,

[...]

Another test, you could plug the vac. adv. tube/line, cap off the carb port and ride it that way, and see if you get any pinging under WOT!? The vac. adv. isn't that necessary for regular running, just provides for more fuel economy and smoother throttle response under cruising low load/throttle conditions!
T.C.

Ah. that looks like the more >>FUN<< test. I'll give that a whirl after I get my ignition switch worked over. It'll be at least a week & a half before I can do that... I'll let you know.

Eric

[eroellig]

Update...

...job search and "honey do's" have kept me busy the past couple of months. However, I did work on my electrical problem.

I pulled off my ignition switch. I could see where it had discolored the copper wiper inside the switch when it sparked. There was a little buildup there, so I took my small brass brush and shined up all the copper & cleaned the entire area and applied dielectric grease. But that wouldn't explain why the starter had trouble turning the engine over.

So, I started tracing the high current wires. Pulled the engine ground wire off. No corrosion that I could see, but stuck my dremmel in there with a small wire brush wheel & cleaned & dielectriced those connections. Went to the starter relay and found those connections still tight and oozing the dielectric grease from when I cleaned those wires previously. Traced back to the battery.....well what do you know... not one but BOTH FLIPPING BATTERY TERMINALS WERE LOSE!!!! How does crap like that happen anyway????

After tightening the battery terminals, the engine cranks right up & my head light doesn't dim at idle as much either. Funny how that all works out.

Been riding around the area more than ever now. Its nice to be able to walk out & ride when ever I want to. I'm doing my best to get my fill before bad weather sets in.

Now I just need to investigate my high speed pinging issue.