Ran out of ideas 😕 1kt

[davewills4]

Well loosing  the will to live now. Have replaced the cdi  box refurbished the carburettors checked all electrics,  new ignition coil and pickup coil . Everything is set up per manual. But she stil refuses to pull over 7000 when under load  with my fat ass sat on it. Only things not  replaced are reed valves  and haven't  removed the power valves  as they seem to cycle okay. She revs out cleanly to red line in neutral  and ticks over nicely  and starts easily  after a few kicks. Truly  baffled . Please help!!!!

[teezer250]

Hi Dave,
Did you decoke the exhausts as i suggested?

[mboddy]

Are the power valve cables connected up backwards?

[davewills4]

Hi mboddy and teezer, haven't decoked the exhaust yet. I will check but haven't removed the cables since it started running badly. Perhaps the power valves need a service   with a regrease of the parts and seals. Just annoying to remove the head and barrels again for the 4th time 

[mboddy]

make sure engine is properly grounded so that the ignition works properly at high revs.

[problemchild]

Powervalve Position correct?
Powervalve Connector is ok?
Powervalve Cables are in the right way?
Have you tested with powervalve deactivated at full open?
Carbs are ok and setup is original?
Carbs Tuned like F3 Manual?
Throttleslides open full on wot(on both sides)?
Choke-Valves ok and moving?
Oilpump or mixing?
Airfilter original?
Airbox original or "tuned"?
Carb Manifolds ok?
Petcock/Fuelfilter/Hoses ok?
Ignition should be ok as you testet many things...
Flywheel is on correct position? the little metal tap is in?
All Groundingcable are ok?
How many Volts at Battery?
Plugs?
How old are your Crankseals?
Sprayed brakecleaner on the ignitionside crankseal?
Lots of smoke?
Have you shaked the exhaust to see if the inner layer of metal is maybe loose and blocks the pipe?
is the exhaust maybe detuned to 27hp?
Tried another exhaust?
Silencer are not complete coked?
Reeds are ok? Not Broken? even if they are old and not properly closed,they will work as long the reeds are not broken
Have you Checked your wiring by shaking the cables while running? especially around the tripple tree?
Your Brakes are free?

any more ideas?

[m in sc]

grab a set of plugs and a wrench and pack them with you, fire it up, go take a ride on it. warm it up. find a road where you can get it up to 7k and do a plug chop. see what plugs are doing at that rpm under load. that will tell you a bit more what's going on. .02

[rz500guy]

We feel your agony. I agree with some of the suggestions about the power valves and the exhausts.  I would somehow and other chime in, undo the cables and then get it started but have a way to open them all the way with a piece of safety wire or something to see if that is an issue. Figure a way to do it and have it all set up and then try it. I agree about pulling the cylinders. Nothing is catching the mechanical portion of the valves possibly like a bolt that is too long that is in the wrong spot. Exhaust system is one i would not of thought about. I sat mine in a trash container and sealed on end, then filled with diesel and soaked for weeks. Question on de coking them. What do you do put them in a large oven?  After draining mine i stuck a hand torch down each end and let it cook. Be nice to have removable silencers. Walk away from it for a week, come back after a cold beer, glass of wine, or a joint and just look it all over. The one guy asked a lot of question so you need to answer them. Difficult to diagnose without putting a hand on it.

[davewills4]

Thanks for all the advice, quite a list of things to tick off quite a few have been looked at.  Latest thing I have done today is remove baffles and have them soaking in caustic soda  they were really gunked up to a point wher couldn't see any of the small holes in them . Also filled up exhaust with caustic  and will let it soak for 24 hours then see how clean it is.
Cheers Dave

[ypvs250]

hey Dave  ,Just lately ive had 3 bikes like this ( 1 tzr ,1 tzr125 and a tdr250) and all 3 the power jets had been cleaned with a drill one was 2mm .they should be .5-.6mm .easy test take the airbox lid off and have a blast up the road just to see if it revs road ,Please dont do this for to long because it could be very lean then .
Also another way was thewith the exhaust off its soaking wet with fuel .

anther one to check ,is the oil pump set up as per the service manual  (not the shimming ) but the cycling and and lining the marks up .

hope you get it fixed soon

[oldiggy]

Agree as I never liked the look of your l/h piston looks grey to me you don't want to fry your new pistons. In December post you said bike was cured did it suddenly started running bad again on road test ?. I've read all your previous posts on this bike and problems go back 7 years an exhausting read hope it all ends soon.

[davewills4]

Well happy news. After decoking the baffles  and exhaust for a couple of days in caustic soda.  The old girl is back revving freely up to 10000 in every gear feels like a different bike. After all the bits replaced and checked it was probably the only thing I didn't consider. Thanks to tezzer for suggesting it. Makes sense when you think about it old girl couldn't breath.  Can only thank you all for your input this forum is a life saver. Cheers Dave 

[Mojoracinguk]

Thanks for confirming a fix.....Nice to see a thread get a proper resolution 

Happy riding