troubleshooting a troubled bike

[DrtRydr23]

it has ran with the plugs in, and but I am going to buy another set just in case. nothing wrong with having a spare set. But I think I may have found the problem. Finally found a screwdriver small enough to get the pilot jet out, and it was clogged fully. I also did test on the floats to see where the fuel was sitting, and it was way low. so I have re-done the floats and clean the pilot jet out completely. going to re-install them all tonight.

I've done the float thing before.  I adjusted them while off the bike, then when I put the carbs back on I was flooding one cylinder, and the other seemed lean.  I took them back off and rechecked and somehow got the floats way off.  I ended up readjusting the floats, then checking each side at least a dozen times with the caliper to make sure they were in spec.  Once I was satisfied I reinstalled and it was much better.  It's so easy to jack up the float adjustment.  I have tried the clear tube method, but found that I can get them adjusted well with calipers on a bench rather than trying to do it on the bike.

[maddietheblond]

It could most likely use a few more moments of adjustment, but i am slowly getting it right. But, I installed another NEW set of spark plugs, new fuel lines (the old ones were getting pretty gross), and cleaned and re-installed the pilot jets. Low and behold, IT RAN! but I did have to jump it off the suburban. I let it run for a bit, then took it for a spin around the block. Did great until I went above 4Krpm and then it bogged down, lights went dim etc. I tried to push through it and it just drained the battery solidly. pushed it back up the driveway (30degree grade, no fun) and let it sit for a minute. Jumped it again and it ran. so I am going to assume that the battery is just not holding enough charge to compensate on the heavier accelerations. getting paid tonight, will buy a new one tomorrow.

[radodrill]

Have you tested the stator and the regulator/rectifier?  It could be an issue with the charging circuit rather than the battery.

[maddietheblond]

I have not tested them under load. Going to put a new battery in, start it up, then check what voltage it is putting out.

[radodrill]

I have not tested them under load. Going to put a new battery in, start it up, then check what voltage it is putting out.

You can actually test them without the bike running.
The stator should have 3 wires coming from it.  First unplug the stator.  With a multimeter, make sure there is no continuity between any wire and ground.  Measure the resistance across 1-2, 2-3, and 3-1; all three of these readings should be similar (around 0.2-2.5 Ohm).  If these check out, the stator is OK.  If any wire has continuity to ground or there are any wire pairs with no continuity or different resistance, then the stator is bad.

The Regulator/Rectifier should have 5 wires; 3 going to the stator, 1 to +, and 1 to Gnd.  Unplug the regrec.  To check it you'll need a multimeter (MM) with a diode setting.  Start with the MM red to + and test each of the wires going to the stator, then connect the MM black to + and test the stator wires again, repeat this test of the stator wires to Gnd.  Of these 12 tests, you should have 3 that pass to + and 3 that pass from Gnd; the other 6 tests should fail.  If this checks out, then the reg/rec should be good.

[The Buddha]

If you have a sealed battery in side ways - if it tips - as in you accelerate, or go uphill, the positive post of the battery will hit the battery cage and short itself. Make sure that's not happening.

Else dying @ 4k could be alternator and battery, but battery dont know its 4k, battery will die @ 2k if you run it long enough.
OK higher rpm = higher draw for spark plug etc, and its covered by the higher output from the alternator ... OK you may be not getting anything out of the alt, but the higher draw @ 4k sends the battery to its doom. Maybe.

Anyway if the issue re occours - look at your carb again.

Cool.
Buddha.