Hey everyone, weird frustrating issue I've been chasing for weeks. 2005 660r.
I started the bike up to prep for desert season, new gas, charged the battery, cleaned air filter, oil, etc.
It ran great, fired right up and rode like it did when I put it away. (Yes I drained the carb before storage). I brought it out to the desert the following weekend and put my volt meter to the battery before trying not start it, I just wanted to make sure it held it's voltage. There was a small arc when I put the meter probes to the battery terminals and then it was very hard to start. I ended up bump starting it and when it finally started it sputtered and popped like crazy. It was ridable for the day but it never cleared up. I didn't think much of the slight arc when I was using my volt meter. I cleaned the carb, didn't help. I replaced the carb, no change besides a slightly smoother idle. Since then I've replaced the CDI, the starter relay, spark plug, coil, new air filter... No change. I checked the fuel hose, the petcock/tank filter, all was clear and clean.
When it's choked, it revs better but still backfires. When it's hot and unchoked, it starts to rev good but will not hold it's rpm when wide open, it bounces off the top.
Revs pretty good when I cover one side of the intake in the air box, but some fuel shoots into the air box when I do that.
Once I get it to rev cleanly without the choke, as soon as I put in gear and try to ride it, it wants to fall on it's face. It will roll around but when pushing the throttle more than a quarter, it loses it all and I have to pull in the clutch and gently rev it to keep it alive. Bike is stock besides a big gun evo r slip on exhaust that has been on it for years.
I'm running out of ideas here! I'm becoming more and more convinced it's an electrical issue.
I started the bike up to prep for desert season, new gas, charged the battery, cleaned air filter, oil, etc.
It ran great, fired right up and rode like it did when I put it away. (Yes I drained the carb before storage). I brought it out to the desert the following weekend and put my volt meter to the battery before trying not start it, I just wanted to make sure it held it's voltage. There was a small arc when I put the meter probes to the battery terminals and then it was very hard to start. I ended up bump starting it and when it finally started it sputtered and popped like crazy. It was ridable for the day but it never cleared up. I didn't think much of the slight arc when I was using my volt meter. I cleaned the carb, didn't help. I replaced the carb, no change besides a slightly smoother idle. Since then I've replaced the CDI, the starter relay, spark plug, coil, new air filter... No change. I checked the fuel hose, the petcock/tank filter, all was clear and clean.
When it's choked, it revs better but still backfires. When it's hot and unchoked, it starts to rev good but will not hold it's rpm when wide open, it bounces off the top.
Revs pretty good when I cover one side of the intake in the air box, but some fuel shoots into the air box when I do that.
Once I get it to rev cleanly without the choke, as soon as I put in gear and try to ride it, it wants to fall on it's face. It will roll around but when pushing the throttle more than a quarter, it loses it all and I have to pull in the clutch and gently rev it to keep it alive. Bike is stock besides a big gun evo r slip on exhaust that has been on it for years.
I'm running out of ideas here! I'm becoming more and more convinced it's an electrical issue.
