im open now to anything even big hammer on it

[minkathecat]

Done so far

Head regrind valves in
Hone bores
New rings fitted
Carbs been in ultrasonic tank twice
All air ways checked and clear

Coils check getting 12 volts
Connections and voltage on cdi checked and ok
Coil ohmic resistance 3.5
And a good spark
Continuity of wires checked from cdi
Have bridge prop stand note

Camshaft set up at 20 pins
With the no one and 4 pistons at TDC
In any case you can not get 180 deg out because of cam orientation due to line up marks But checked reversing coil terminals backfired so im right way round

Signal generator checked out at 98.2 ohmic value
Is their a difference between 53 bhp and 95 bhp on this item I know the sprag clutch is different for the 2 bhp models.

It appear like im not even wetting the plugs for some reason the large jet is the main jet or is it the smaller one don’t think so their would be nothing going past the needles

I should be at least getting bikefiring sqirting spray mist into the carbs.

[SevenThreeSeven]

It appear like im not even wetting the plugs for some reason the large jet is the main jet or is it the smaller one don’t think so their would be nothing going past the needles

Sounds like there's something fundamental that's wrong here...

I know you've tried to be careful and correct in reassembling the engine but it sounds like there's no suction being created by the engine. Without suction the carbs (even if they are in perfect condition) will not flow any fuel to the cylinders. Maybe a valve timing setup error? (Not trying to insult or offend anybody) Have you visually verified that with your current valve timing there's definitely a piston down-stroke happening with exhaust valves closed and intake valves open?

just trying to help.

[Variablevalves suck]

Pulse pick up is same for all models with a reading of between 97 and 108 ish ohms.

If the plugs are dry its usually the pilot jet that's not flowing, common fault is parts the wrong way around, check you got everything correct - screw with spring on then washer then oring.

Things that will completely screw it are wrong model cdi, starter clutch or cams,
You sure these are all matching as they will back fire but not run.

You know when its got good compression just off the sound from turning it over, they just sound right and you can hear the air being pumped through the air box, sweet sound.

[minkathecat]

yep air screws r correct spring washer o rings and new from list on here set them at 2 for starters
been re looking at wiring today. looks ok with good spark
im now suspecting the sprag clutch and looking for 53 bhp one it could be the wrong type and i will re check the cams to it then if that is ok the sprag clutch on 59 bhp is like cast looking and the one on mine looks like pressed steel
then we r looking for some fzr600 pistons to machine up
ONE THING I DID NOTICE THIS MORNING A WIRE ADDITION TO THE FOOT STAND COMING FROM THE SMALL PLUG ON THE CDI IN GREEN AND WHITE (NOT SHOWN ON MY WIRING DIAGRAM tHE SMALL PLUG HAS THE PULSE SIGNALS SENT


I TAKE IT THE PILOT JET IS THE SMALL JET TO THE LEFT I THINK OF MAIN JET.
HM CDI I WILL POST UP LATER CDI NO YA COULD HAVE A POINT THEIR BUT IT WAS RUNNING BEFORE EVEN THOUGH IT NEEDED A LOT TO START THE THING, JUST SEEMS LIKE IVE MADE IT WORSE NO BETTER LOL

IF AT FIRST IT DONT WORK TRY TRY THEN GIVE UP LOL

MANY THANKS FOR INFO ANYTHING CONSIDERED EVEN BIG HAMMER JOB AND FIT HORNET ENGINE

[Variablevalves suck]

The wire from the near the gear lever is the gear sensor that tells the CDI which gear the bike is in and is used to restrict the top speed to 180km.
Best thing you can do is get a 1.5k ohm resistor from maplins and then connect that between the cdi and the frame so the bike thinks its always in a low gear, don't connect the other side from the engine!

[minkathecat]

http://s1056.photobucket.com/user/catch ... ent&page=1
pics above of wire on small connector in green

above pic variable The green wire out the pulse sensor connector which is additional to my wiring diagram is going to the nutral indicator switch how this tells it what gear when its just nutral switch we could be at cross purposes here when i wrote info MAKES YA WONDER WHEN YA PICK UP A SECOND HAND BIKE JUST WHAT THE HELL PEOPLE HAVE ADDED WRONG PARTS ETC ETC then cos it dosnt run right sell it on and when u have no proper manual your sort of firing in the dark thinking its the correct part. seen any sprag pick ups for sale for mine i want one even just as a spare.

The cdi nos i can make out middle bottom nos looks like 8b74
And th other cdi no on the higher bhp motor well cant make them out but the unit is slightly lomger than the above in size
I tride this on to see if their was a spark at the coils to see if it was a good unit but alas no spark so that wants doing up i looked at your info on repair for this and might do that later on so as if i want use the sprag clutch unit and cams with the cdi that give larger bhp but im more conserned with what i have at the moment.
I have been looking into teflon coating them bores cos i feel honing them out has not proved better seating of the new rings but hindered it
regards john

[stripes1976]

FYI
Cold compression test around 140-150
Hot compression test should be upwards of 180
These engines expand a lot!!!
When I'm back next week I'll give you another call. Sorry I cut it short last week but was really pushed for time. You can call me today but it costs me a fortune to call from here.

[minkathecat]

ok mate
bores not near this 100 PSI WAS HOPING AFTER FIRE UP VALVES SEAL BETTER AS WE DISCUSSED LIKE GSXR750 need my compression tester doing up leaking a bit at snap on connector o ring
think this is either teflon coating or the fzr600 piston mods to fit SHIT SHIT LOL
BUT I WOULD NOT BE SUPPRISED AT SPRAG CLUTCH FAULT
REVERSED WIRES TO COILS POPING BANGING BACK THROUGH EXHAUST WHICH IS BETTER THAN I GOT KNOW LOL

I WISH U WOULD FIND THAT MAUAL LOL

[willandrip]

http://s1056.photobucket.com/user/catch ... ent&page=1
pics above of wire on small connector in green

Dead link

[minkathecat]

http://s1056.photobucket.com/user/catch ... ent&page=1

https://www.youtube.com/watch?v=NH6OlEoGwv4 first strip bit of info where i was up to

https://www.youtube.com/watch?v=ixI3Th-K52M z200 rusty heap found in a garage

https://www.youtube.com/watch?v=Xp2rrvVIadc

try this again for some reason paste didnt work at top link