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Barn Find - need help please


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Bloody hell Grum, I’ve gone cross eyed. You need to come out of retirement and open a motorcycle shop, specialising in Viffers. I’d be a customer!

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8 hours ago, VFR78 said:

Bloody hell Grum, I’ve gone cross eyed. You need to come out of retirement and open a motorcycle shop, specialising in Viffers. I’d be a customer!

But why does Grum start writing in ancient Latin whenever he talks about electronics😳 I don’t understand, literally. 

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Hello everyone.  Per Grum's and Danno's suggestions, I confirmed all injector and coil wires are the correct color and I measured all sensors for voltage and resistance.  I also pulled the throttle bodies and replaced all vacuum lines and made sure the L shaped vent hoses are connected to the underside of the airbox.  I found no leaks in the old hoses or T's, and the bike still behaves the same and will not start.  There are still no Fi codes, kickstand down, in neutral, kills witch run, ignition on.

 

There coils appear to have low output but video from my previous post shows decent spark.   I am beginning to wonder if the problem is a combination of the coils and possibly fuel pump too.  Let me explain.  The manual (p 5-48) says to turn the ignition on for 10sec and measure volume from the return hose.  The problem though, is the fuel relay kills the pump after (approx.) 1.5sec. and there is no way to perform the test.  This is what led me to jump the relay (improperly), and fry the ECU.  I was never able to get ANY fuel coming from the return line.  I tried direct 12v to the pump and bypassing the relay.  The only measurement I could get was the output volume of the mainline without a load.  I do not have a fuel pressure gauge with a banjo connection.  While the volume was good, I am starting to suspect the fuel pump may not be up to par under load.  Everyone I talk to says to replace the pump, it's 20yrs old after all.  What do you guys think?

 

Sensors & Electrical:

I am working with a cheap multimeter and my understanding of the settings is a bit fuzzy, please bear with me.

 

ECT:  2.44 Ohms  4.19v        (voltage slightly under spec 4.75-5.75)

 

MAP:  4.96v     WITHIN SPEC

 

TPS:  4.96v,  continuity exists between wire harness ground and TPS ground, no continuity between light green & ground -                     WITHIN SPEC

 

IAT:  2.61 Ohms  4.95v  WITHIN SPEC

 

Baro:  4.96v  WITHIN SPEC

 

COILS:  The manual has no specs for primary secondary resistance, but 3-5 Ohms seems to be the standard.  For voltage I set the multimeter (with peak voltage adapter), DC to 200v because the next lowest is 40v (this is where my understanding is fuzzy -not sure how this affects the reading).  Spec is anything over 100v so all of these appear to be lower than spec.  Again, not sure about the settings and how that effects the reading.  Please let me know.

 

Coil 3 - Primary 3.2 ohm, Secondary 2,021 ohm  -  Peak V 47.6

 

Coil 1 - Primary 3.2 ohm, Secondary 1,951 ohm  -  Peak V 51.9

 

Coil 2 - Primary 3.0 ohm, Secondary 2,017 ohm  -  Peak V 52.1

 

Coil 4 - Primary 3.0 ohm, Secondary 1,976 ohm  -  Peak V 51.6

 

That's all I have for now,  It's been a journey and still looking forward to getting her going.  Thanks all

 

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4 hours ago, Jroberts3 said:

I was never able to get ANY fuel coming from the return line. 

 

 :idea3: Ah Ha......This appears to be a Revelation!......

 

Fuel Flow Inspection test is on the Return Line NOT the Main Line. Looks like your bike is not starting due to inadequate fuel rail pressure!

 

Think you should have addressed the issue of No Return Line Fuel Flow way back, would have saved an awful lot of unnecessary checking and testing!

 

Assuming you don't have a completely blocked return hose, you could have a stuck closed FPR, or more likely a faulty Pressure Relief Valve within the pump or some other fault with the pump itself.

 

Have a good read of the Technical Features section pages 21-20 to 21-22.

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@Grum  With the bike having been parked for an extended period of time (years possibly), do you think there is any possibility of part of the fuel line or related components being clogged from the Ethanol used in US fuel?  

 

 

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7 hours ago, jroberts427 said:

@Grum  With the bike having been parked for an extended period of time (years possibly), do you think there is any possibility of part of the fuel line or related components being clogged from the Ethanol used in US fuel?  

 

 

Good point. Can't really answer that, good chance it will increase corrosion within the tank as well as the potential to absorb moisture because of its hygroscopic nature, who knows how this may effect components in the pump and fuel lines. Possibly the reason why he had to replace the injectors as two of them wouldn't pulse.

Do some research on "Phase Separation" issues with Ethanol blended fuels!

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