Engine won't rev past about 4600rom

[10spd]

Thanks. Need to check into that.

[videoarizona]

I really think at this point, you need to cut the TCI open and see what's going on (if anything) within that unit. If it's clean and all looks good, it still could be failing. BUT, sure seems to me to be TCI related. Since the TCI is the computer to determine plug firing...it would make sense to at least see if it can be ruled out as a source of the problems.

Thinking out loud, here....

[10spd]

I am going to get a new TCI box from dingy & not worry about looking in mine.

[10spd]

Got my new box from dingy. Fixed my issues. Bike runs great now

[Patmac6075]

Beau-Kat, if I were you I'd put a shout out (new post here or Watering Hole, or maybe Classified/Wanted) and see if somebody has a known good TCI would lend you theirs....Maybe offer next day shipping both ways or something? This way you could rule out TCI issue once and for all.

[Beau-Kat]

Good idea.

Gonna do that.

Thanks.

Rusty

[Beau-Kat]

OK guys. Here is an update after borrowing a good TCI from Dingy and doing some testing.

 

I had already checked all of the electrical connectors that I could identify as having to do with ignition. All checked, seemed, or tested good with no corrosion.

 

So I was getting stumped.

After going through all the connectors I could think of, I had #4 showing poor spark and then the problem switched to #2, and then other crap started happening. It was like chasing a rabbit down a hole. The problems kept moving. Then, last night, I discovered I had more than electrical issues.

 

So, here's where I stand:

After swapping Dingy's and my TCIs back and forth a few times during testing, I got spark on all cylinders with both TCIs. It must have cleaned up those connectors a bit with the plugging and unplugging. So that tells me my TCI is good.

But bike still ran crappy and still had sooty plug on #4 and cold pipe on #2.

Drained my carbs again last night. Saw fine black specks in all of them. Had just serviced all of them and done the valve service too a few months back. Figured the specks were caused from manipulating the old deteriorated fuel line during carb service. I did not replace the old fuel line at carb service because all the fuel line I had in stock was too large. Lessoned learned for next time. So, I pulled the carbs last night and went back through them.

Found this with #2 carb:

Somehow, I failed to screw the low speed jet in all the way, so it was loose in its port. I must have gotten my small screwdriver down beside the jet instead of in the slot in the top of the jet, turned the screwdriver and felt the jet get "tight", and quit screwing it in. Only it wasn't all the way installed.

I had also put the low speed's black rubber plug in the dummy port on the other side of the main jet port instead of in the low speeds port. Don't know what effect that might have had on operation.

Found this on #4:

Debris in the tiny air port for the diaphragm (the one at 6 0'clock with the o' ring that is visible with the diaphragm cover removed). Go that cleaned out.

Thoroughly cleaned and blew out all ports on all carbs to get the black specks out.

Checked all float levels and found them to still be good.

Although my diaphragms looked good and were supple, I installed all my brand new diaphragms.

Installed new fuel line and new filter. Tested pump operation.

Started bike. It started quickly and is firing on all cylinders now. #2 pipe getting hot like the others.

Synched carbs.

Bike seems to rev fine on the lift. Haven't test ridden it yet.

 

Note: After the exhaust gets hot, when revved to about 2.5 to 3k for several seconds, bike starts blowing black "rich" smoke from left side exhaust. I think this is residual fuel smoldering that built up in the exhaust system during all the time #2 wasn't firing. Did the same thing from the right side exhaust, but that cleared up. Remember, I had trouble with spark on #4 cylinder for awhile also.

I think the left side smoke will probably clear up during my riding test.

 

I'm gonna get all new spark plugs tomorrow and install them.

As soon as I can get a highway test with my TCI and then Dingy's, for comparison, I'll be sending his back to him.

I can't thank him enough for the loan.

 

However, I'm gonna get an Ignitech anyway. I'll keep the old TCI for a "just in case", but want to install the new unit for peace of mind.

 

I want to thank all of you for your responses and good suggestions while I sorted through this issue.

 

Rusty

[10spd]

As Yammer Dan said, dingy is a keeper he helped me with mine.

[Beau-Kat]

Have test run the bike a few times with my old TCI installed and then swapped to Dingy's borrowed one. No difference between the two.

With either TCI, runs dang near perfect to me. Can't sense a miss or a bog. Plenty of smooth power all the way to redline in any gear. And I haven't even installed the new plugs yet.

Problem seems to be solved.

Have received the Ignitech in the mail, have the new plugs on the bench, and a new spade type fuse block to swap out the old glass fuse one on the bike, but had to go to Kentucky over the last few days and just got back.

Hopefully, gonna try to get it all straight this week.

[10spd]

Ok after about 800 miles in 3 weeks of flawless performance. I believe I am ready to take off on nice long ride. So tentative plans are to head south for a couple of days.