I finally worked out that the engine kill switch on my bike is wired up completely wrong.
The switch is open when set to "run" and closed when set to "off". This is the reverse of what it should be, and lead me to think that the kill switch wires should be open when trying to set the power valve to the "Hi" position with the TPS disconnected. Wrong!.
In order to set the power valves, you must have the Kill switch set to "run" and this means that the two Black and Black/White wires should be connected. Then with the TPS switch unplugged, turn on the ignition key and the power valve pulley will rotate to where the computer thinks the fully open position for the power valves is. Now you can adjust the cables so that the power valves are exactly in the fully open position.
Note that the TPS connector block is a mongrel of a thing to pull apart.
Finally, after a bit of head scratching due to the incorrect kill switch leading me astray, I have been able to get my power valves operating correctly and now have spark at the spark plugs.
There is now light at the end of the tunnel. I just need to source a few little bits and do some minor work and it will be finished and working.
Things I need to source:
00)Correct kill switch! 03/01/2012 in the post.
01)Mini wiring loom for tacho/temp gauge. (bidding on Yahoo!Japan) 02/04/2012
02) Rear bottom fairing mount bracket.
03)Speedo cable. (bidding on Yahoo!Japan)02/04/2012
04)Radiator cap 06/01/2012 Arrived in post from Paul along with kill switch.
05) Pillion foot pegs. (bidding on Yahoo!Japan) 02/04/2012
06)Upper front RH side fairing mount that also supports small two-stroke oil tank 02/01/2012
07) Dzus fasteners for fairings. (Have fitted some but need more)
08) Rear seat latching mechanism. (bidding on Yahoo!Japan) 02/04/2012
09)Front Park Light and wires. 22/04/2012
10) Radiator bottom bracket. (bidding on Yahoo!Japan)
11) Brake hose clamp on bottom triple clamp. (bidding on Yahoo!Japan)
12) Front brake reservoir mounting bracket.
Things I need to do
1)Tape up the wiring loom after having pulled it apart for thorough inspection 02/01/2012
2)Fit new carby float bowl seals. 04/01/2012 The leaks basically stopped after having petrol in the bowls for a few days.
3)Fix broken air valve wires (green connector block)
4)General assembly of carbs, two-stroke oil tank, radiator, thermostat and radiator overflow tank and exhaust pipes. 04/01/2012
5)Make the fairings fit. Not a small job.
Unfortunately, it is the holiday period so it will take a bit of time to get this sorted out. Maybe about another 2 weeks. There is now nothing but some assembly time stopping me from firing up the engine. :-)
The switch is open when set to "run" and closed when set to "off". This is the reverse of what it should be, and lead me to think that the kill switch wires should be open when trying to set the power valve to the "Hi" position with the TPS disconnected. Wrong!.
In order to set the power valves, you must have the Kill switch set to "run" and this means that the two Black and Black/White wires should be connected. Then with the TPS switch unplugged, turn on the ignition key and the power valve pulley will rotate to where the computer thinks the fully open position for the power valves is. Now you can adjust the cables so that the power valves are exactly in the fully open position.
Note that the TPS connector block is a mongrel of a thing to pull apart.
Finally, after a bit of head scratching due to the incorrect kill switch leading me astray, I have been able to get my power valves operating correctly and now have spark at the spark plugs.
There is now light at the end of the tunnel. I just need to source a few little bits and do some minor work and it will be finished and working.
Things I need to source:
00)
01)
02) Rear bottom fairing mount bracket.
03)
04)
05)
06)
07) Dzus fasteners for fairings. (Have fitted some but need more)
08)
09)
10) Radiator bottom bracket. (bidding on Yahoo!Japan)
11) Brake hose clamp on bottom triple clamp. (bidding on Yahoo!Japan)
12) Front brake reservoir mounting bracket.
Things I need to do
1)
2)
3)
4)
5)
Unfortunately, it is the holiday period so it will take a bit of time to get this sorted out. Maybe about another 2 weeks. There is now nothing but some assembly time stopping me from firing up the engine. :-)
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