Feels like ignition

[The Buddha]

Did you install that seal the right way ?
Cool.
Buddha.

[mr72]

I think so! Spring side towards the oil.

[MaxD]

What a trial this has been.  I'm checking every day to see the latest installment.  Hope it turns out well!

[The Buddha]

The crank is gouge free ?
Didn't you rebuild the upper end of this bike ? Was it before or after, and done by a shop - Sorry I forgot and am too lazy to go searching for the thread right now.

Cool.
Buddha.

[mr72]

yeah I had a shop do a top end rebuild about 5k ago. They didn't check the crank or do these seals afaik. The part of the crank I can see looks good.

[The Buddha]

The seal was from before that ?

I've literally never seen that seal go, is it possible they opened that side to turn it over and managed to get the seal gouged up somehow.
Cool.
Buddha.

[mr72]

No, I replaced the seal after they did the work. I must have damaged it somehow putting it together.

[The Buddha]

I cant imagine you damaging it, matter of fact I cant imagine a 3 thumbed gorilla damaging that seal that way.
But I've barely gone past seeing one on a motor. You're definitely the champion of the right crank seal.
Cool.
Buddha.

[mr72]

I may have a special talent for screwing up. Who knows. But the good news is I have a new seal in there and it's viton so it should hold up better anyway.

Put the bike all the way together this morning and it started instantly, better than it has in a long time. I didn't test ride yet, just started and ran it for about 1 minute. I'll try to take it for a ride to go get gas later today and see if anything is better. At least I need to get back to normal working and no gas in the crankcase.

[Bluesmudge]

I've literally never seen that seal go, is it possible they opened that side to turn it over and managed to get the seal gouged up somehow.

Buddha, I have also had that seal go. And I followed a Youtube video on how to replace it so whoever made that video also had the seal go.

mr72, you are not alone dealing with that seal. I remember the seal replacement process being difficult insofar as not knowing if the install was done properly and no way to know until you have installed all the gaskets and filled the bike back up with oil. Worked first time for me thank goodness but it was not a fun process. Hope your new seal holds up!

[mr72]

That same seal replacement has come up a few times since I have been on this forum, so I know others have had issues with it as well.

I think the only trick is pressing it in without distorting it in the process. I used the old seal to push it in. First started with a rubber mallet and a 31mm socket to get the new seal started and then used a bolt/nut/big washers setup to press the seal in gently with the old seal as a guide between the washers and the new seal. Worked fine for me. It's only tricky because you have to take the apparatus apart once or twice to verify if the new seal has seated fully since you can distort it if you go too far.

When I did this before the seal was installed right and everything good to go before I put the side cover back on. So either I damaged it putting the side cover on or it was damaged later in use. Who knows. Probably was my bad.

[mr72]

Just used the bike for an errand, got gas, rode it just a bit sort of as a test ride.

There was 40 miles on the trip odometer since I had previously filled it with gas. I put 4.9 gallons in (!). I didn't even know the tank would hold 4.9 gallons! Yes. that's just over 9 miles per gallon!

I think it was running rich.

The 9.5K sputter is utterly gone. Bike also idles at 1100 beautifully and essentially does all things well. Wheelies all too easily in first, revs to 11k no sweat under WOT, all that jazz. But there are two issues now, and I remember it was trying to fix one of these is why I went to the 127.5 jets in the first place, and that's an off-cruise or off-idle hesitation. Looks like I need to shim the needles. Fortunately I can do that with the carbs and airbox on!

Which dovetails with my other issue which is again the fuel lines are leaking at the tank. I need to cinch down the hose clamps a bit tighter. But of course I have to take the tank off again so I can fix that then. And then while it's apart I will probably finally change that valve cover gasket and get rid of the last oil leak.

Oh yeah, the right side crank seal does not leak. So that's a success.

I might get to the bottom of this thing yet.

Also the plain steel threaded rod I am using for a shifter linkage is rusting a little bit, so some CLP might be in order for that. And I need to loctite a couple of the footpeg bolts, and also probably make a new pedal cap for the rear brake pedal, something thick, since it's kind of low compared to my foot. And the rear brakes need to be bled and I have a new set of pads. Plenty of stuff to do there.

Next week I have to get surgery on my left foot and won't be able to wear a shoe for a few weeks so I'll spend that time getting the old GS dialed in but not able to ride it. It's not bad timing because that'll also be the first weeks of July which are too hot to ride anyway. My dad is picking up a TU250X project bike this week and he intends to turn it into a proper scrambler, so I will help with him tinker with that too.

Anyway, presumably I'm on the right track with a washer or two on the needles to fix the off-cruise hesitation.

[mr72]

Alright, over the weekend, I shimmed the needles with two brass #4 washers on each carb, and fixed my fuel leak.

Test ride today. The bad: bike basically won't run unless it's on PRI. Guess I need to go make sure I didn't crimp the vacuum line while putting it together. It has happened before.

The good: bike runs like a scalded cat. The hesitation at part throttle is completely gone. No problem revving to 11k.

The weird: popping and crackling a lot more on decel than it ever has. A lot more. Even pops and crackles some when the choke is on (or at half) at idle. But it runs just fine so I'm not sure I care. Running great under load and WOT at all revs and also at part throttle, that's what I'm after. I'm sure I'll get used to the popping and crackling.

[The Buddha]

Crackling and popping on shut throttle actually is a sign its working fine - oddly it also reduces with extra carbon deposited everywhere.
The prime thing - make sure you don't have a vacuum leak- Will cause the popping to get worse as well.

Cool.
Buddha.

[mr72]

Yes I agree the popping and crackling is a good sign. I'm just used to my FI bike that basically doesn't do it at all.

Either the petcock vac line came loose at the petcock when I was putting it all back together, or it's pinched between the frame and the clutch cable. Either way I can fix that easy enough. I am having surgery on my foot day after tomorrow so I'll be off the bike for 2-3 weeks. Plenty of time for me to find and fix the vacuum issue.

Just really glad I got the running issues sorted.

So the magic was 125 jets and shimming with two washers. I first tried to solve the part-throttle hesitation with a bigger jet (127.5) which it appears caused too-rich at the top end and likely fouling plugs causing my 9.5K rpm sputtering (misfire). But it fixed the part throttle mid rpm hesitation. 132.5 jets made everything worse, going back to original 125s and two washers fixed everything.

Now I won't mind if I never have to pull those carbs off again.

[The Buddha]

Good luck with the surgery. Bike fixed - 

What surgery ? Topaz ? for plantar faciitis. I had in 2013 - basically 20 yrs of pain gone. Just the 3+ month recovery was a PITA though.

Cool.
Buddha.

[mr72]

neurectomy. That is, remove neuroma and part of a nerve. Should be able to walk on it immediately and only recovery is stitches in the top of my foot, which means I can't wear ordinary shoes for a couple of weeks.

That couple weeks of downtime from riding gives me time to get everything fixed up plus help my dad fix up the tu250 he just bought to turn into a scrambler. And first of July is really too hot to ride motorcycles anyway.

[The Buddha]

Aaah OK. Don't know nutting about that. But GLWT Surgery

Cool.
Srinath.