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Old 03-01-2007, 09:32 PM   #1
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Please help. Engine will start and ideal good. Engine runs well up to clutch engagement then starts to loose power. Sputters. Some times engine will accelerate past 6,000rpms and go up to 7,500 rpms. Most of the time no higher then 6,000 rpm. I have followed all the trouble shooting in the maintenance manual. The stator has been replaced no effect, the coil has been replaced no effect. The clutches have been overhauled no effect. the throttle postion sensor has been checked out and reset. the compression is at 108 on both cylinders, The spark plugs have been changed, The fuel pump is good and the fuel pressure is at 37 psi at the rail. The air box is unrestricted, the exshust is unrestricted. I scoped the engine and it looks good no marks everything is clean. I did notice that one cylinder has carbon on the piston that looks normal but one piston apears to be washed clean and is wet. The carbon is almost all washed off. the spark plug for that cylinder is very clean but wet.The reed valves also look good when I scoped the engine. When the engine is idealing the cylinder is working when I remove one plug at a time. Also the cylindars apear to alway be at the same temp when I touch them but it is liquied cooled. The EFI computer has no codes when running. To me it seams like a fuel problem or a ignition problem under power. The timeing sensor did check out when I ohmed it out. I'm lost need a good efi technicians input. Thanks Mark
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Old 03-02-2007, 12:48 AM   #2
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Sled: 1999 zr 600 efi
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sounds like you covered it. one thing you can do is when it is running, spray ether (very little) at your crank behind your primary clutch. this is a quick way to find out if your seal is bad. if your block is leaking, it will show signs like it is an electronic problem. if it revs up, the seal is bad.
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Old 03-02-2007, 08:11 AM   #3
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I have been told that I will try it. WOULD THAT CAUSE THE PISTON TO LOOK VERY RICH. THE CARBON IS ALMOST WASHED OFF. THE RICH CYLINDER IS THE ONE BY THE STATOR.
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Old 03-02-2007, 02:56 PM   #4
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Sled: 1999 zr 600 efi
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i havent seen this as of yet but it is one of the things i check just to eliminate that possible cause. im sure that it would affect the way the fuel is delivered to a point.
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Old 03-02-2007, 03:27 PM   #5
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I TALKED TO A LOCAL TECH AND HE THOUGHT MAYBE THE 108 COMPRESSION ON BOTH CYLINDER WAS LOW FOR A 500CC ENGINE. HE SAID THE 500CC ENGINE DOSENT HAVE A LOT OF LOW END? ANY THOUGHT! HE ALSO MENTIONED THAT HE HAS SEEN FUEL INJECTED ENGINE SHOW A NORMAL CYLINDER AND A RICH ONE? I THOUGHT I NEW SOMETHING TILL THIS ONE BIT ME. THANKS FOR YOUR HELP. I'm still going to spray carb cleaner or starting fluid around the crank seals.
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Old 03-11-2007, 08:23 PM   #6
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Well after performing a top end the problem was still present. With a external temp gauge one cylinder was running 250 degrees less. I swapped the fuel injectors with no luck. The final thing I performed was changing the Timing sensor or pickup. This was the problem. I hope this post can help someone. Please note the timing sensor ohmed out ok.
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Old 03-12-2007, 08:49 AM   #7
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What involved in changing/testing the timing sensor??
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Old 03-12-2007, 10:02 AM   #8
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Thanks for supplying the solution..Something I never would have guessed to cause the problem
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Old 03-12-2007, 07:01 PM   #9
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The timing sensor change wasent to bad. I did have the air box off and then pulled the throttel body off and out of the way. I had to roll the sled over and remove the belly pan so I could remove the engine mount and 3 bolts. That gave me room to get to the 2 screws that are loc tighted in. It is best to use a apex #2 screw tip in a 1/4 inch drive socket and socket to remove the screws. There was 2 checks one was with a ohm meter should be around 180 ohms the other is with a peak voltage meter and that should be 1.5 volts or higher. When testing for peak volts there is a special adapter for your meter. I read a post that said to select ac on your meter and then multipy it by 1.414 and that should be the reading you would get with the peak adapter. I hope this helps.
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