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Old 05-23-2006   #1 (permalink)
Senior Member
Supersport 600
 
Join Date: Apr 2004
Location: Newark, DE, USA
Posts: 185
I'm still **** missing on the number three cylinder!!! First I thought it was a loose spark plug lead. Next, I found lots of crud in the in-line filter and thought cleaning it resolved the issue. Now it still misses. I pulled the carbs and cleaned them. No serious crud. The jets let more light shine through them after cleaning and squirting with compressed air.

Check out what I found recently. This is insane. The spark on number three is thick and blue. After several minutes of idling the spark gets narrower and yellowish. A few minutes later the spark disappears.

The first time I observed this behavior I was floored. I shut the bike down for ten minutes and restarted. The spark returned on startup and remained for several minutes before expiring as previously stated. I then swapped both the coil and spark plug lead with the number one cylinder. The same behavior occurred: spark for a while and then none. I shutdown and reinserted the plug lead into the cylinder head. I started the engine. While it was running properly, I jiggled the coil's connections. The cylinder would not die. I jiggled the igniter box's connections...the cylinder would not die. Eventually the cylinder began to miss and finally shutdown. As the bike was running on number two and one I proceeded to jiggle again. I was able to get the number three cylinder back onilne by poking at the exposed wires in the female igniter connector. Pressing the female connector back toward the rear tire made the plug fire. ***, mate!@?

I must have been jostling that connector each time I tore the bike apart trying to resolve the miss. That would explain why I had several hundred happy miles after each troubleshooting session. I bent the first row of pins on the igniter box in order to exert more pressure inside the female connector. Maybe this will fix it. It did not miss for the rest of the day ( on the lawn ).

It was threatening to rain. As I work on the bike on the front lawn I couldn't proceed in the rain. I'm looking forward to finishing the reassembly tomorrow. I would have had it back together if it wasn't for that horrible airbox.

Just how the hell do you get the airbox back on? I've taken it off a few times before without this much trouble. Is there some sort of incantation I must chant before putting it on? I almost kicked the bike over I was so bent about it.
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Old 05-23-2006   #2 (permalink)
Senior Member
Formula Extreme
Favorite Bike: 95 TB & 07 Tiger ABS
 
Join Date: Sep 2002
Location: Corinth TX
Posts: 708
You have my sympathies mate.... I know how that goes!

This really helps with a TB airbox and carbs - hope it does for a Legend.

I'm assuming that right now, you have the airbox and the carbs off. Mount the airbox first and get it snugged down with the drain pipe fitted. Next, screw in an airbox cover bolt on each side - partially, so they are sticking out.

Take two bungee cords and hook them round the bolts and hook the other end round the rear indicators or some other mounting point at the rear. If you have a long bungee, then hook round the bolts and loop it over something at the back. That way the airbox is forced backwards and gives you the maximum space to slide in the carbs between the airbox and the cylinder head.

Hope this helps.
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