*Update*

Made some time to unbutton the bike.  I went into last night fully intending to revert to the original shims and thus their clearances (all around .18-.24) which I know are out of spec, but that was the last time it sounded good.  So I am taking the valve cover off and bump the right exhaust header bolt and notice, wow, this is way loose, wow both bolts are finger loose.

So I measure my clearances, all still greater than .04 and less than .08, with only one < .10 (the .1 wouldnt fit, but the .08 would).  So taking the new found exhaust bolts information into consideration I decide to not change my shims up, instead I put it back together and tighten down those exhaust bolts, both the left and right, all four bolts were pretty loose.  Since they are hex I do not have a hex socket for my torque wrench and dont even know how I would get it in there to tighten down because of the low clearance.

So I get those tightened down nice and good. Put the fuel tank back on, back it out into the driveway and try starting it.  It takes a bit to start, usually does after opening up the valves. Good news! The funny idle noise appears to have gone away!  It sounds much better!

But this time something is weird, its like I dont have any power, for example, full choke, RPM still barely around 2k, wants to die.  I can give it gas and it revs up just fine.  Something is not right, thinking maybe I pinched a hose somewhere.

So I shut it down, remove the tank, check my hoses, all look good, put the tank back on and try to start again, this time a loud backfire noise before it even starts, but then it starts up, feels maybe a little better.  I take it for a spin around the block, and now there is a noticeable lack of throttle response maybe past a half twist, like its getting the fuel but doesn't know what to do with it?

Frustrated I shut it down and head in for the night.

I did a quick search on the forums this morning and found a reference to very similar problem and the disconnecting of one of those little coil dohickeys above each spark plug?  I have done that accidentally before, yanked out one of those spade connectors. 

Question to you guys:

1. Would accidentally removing one of those spade connectors from the coil dohickey cause poor acceleration / act like a pinched hose almost?
2. If I gather right, that coil is responsible for firing that sides cylinder somehow?  Does that mean I was running on one cylinder?

If I am right on number two, I may still have my idle noise funny, if I hook it back up and get that cylinder firing again?

Now the frustrating part, having to wait until I am off work to go home and check if I really did accidentally disconnect one of them!

Are you sure you are using a metric feeler gauge or is it an imperial?!

Metric

Here are the gauges I am using: http://www.ebay.com/itm/300718504269?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

Please take a glance at them and ensure those look right. The lower blades, .02-.03 are realllllllly thin, feels like I am going to tear them.

Wohoo!

Got home, looked under the bike and sure enough, left side ignition coil had a spade connector just dangling there.

Connected it up, bike fired right up, sounded much better!

Took it for a ride, had full acceleration available, very responsive, sounded great, wow, it feels good to have it working properly again! Still had the hovering idle problem but adjusted the idle down a bit and now that seems solved as well!

In Summary:

Funny Exhaust Noise was caused by loose exhaust header

Found Exhaust Header while doing valve check (because I could not figure out what else to do), while buttoning back up accidentally disconnected left ignition coil causing funky acceleration and one hell of a backfire.

Reconnect ignition coil, tightened exhaust header, adjusted idle, all good! *crosses fingers*

Quote from: adidasguy on October 03, 2012, 04:06:35 PM
Carb sync?
Sounds like one cylinder is working harder than the other so you get the PUTT putt PUTT putt PUTT putt

Check plugs to see if one side rich or leaner than the other.
Then do a carb sync.

Reminds me of what I've gone through with Junior's engine(s) and the other bikes.

at first it sounded like perhaps one cylinder wasnt firing. but when throttle applied that improved.