Starting motor after rebuild - Wrist Twisters
 
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post #1 of 18 Old 05-01-2015, 12:58 PM Thread Starter
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Starting motor after rebuild

I just rebuilt my 919 motor and am having the problem everyone dreads after such an undertaking....won't start.

Checked all the plugs and I have spark. Checked the fuel pump and it has voltage when the key is turned on. I also checked that it flows fuel by disconnecting the fuel return line and measured the amount when the key is turned on.

I popped open the valve cover to check the valve timing, the marks still line up.

Checked the plug wires were routed correctly. Even tried swapping the coil signal in case that happened to be switched.

I turn the motor over and it doesn't even act like anything is igniting.

I haven't tried pulling the intake and seeing if the injectors are squirting, and I haven't done a compression test but it feels ok when I turn it over by hand.

Ideas? I'm about to simply buy another bike for the riding season.

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post #2 of 18 Old 05-01-2015, 01:23 PM
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Check your kill switch.

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post #3 of 18 Old 05-01-2015, 01:31 PM
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Check the clutch switch and kickstand switch

2004 919 Uranium

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post #4 of 18 Old 05-01-2015, 01:32 PM
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post #5 of 18 Old 05-01-2015, 03:34 PM
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I don't think the start button will even work if the kickstand or clutch switch are triggered. Fuel supply problem I'm thinking.

2005 Honda 919
If you bite the hand that feeds you, it won't taste as good as the food you were fed.
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post #6 of 18 Old 05-01-2015, 04:11 PM Thread Starter
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Ugh...so embarrassing

Correct, the motor wouldn't even crank if there was a problem with the kill switch. The fuel pump doesn't get power either.

Upon further investigation... I was completely ignorant with my cam timing. Being a little rushed and working nights fogged up my mind lol. I've been building cars for a long time but never messed with wrenching on bikes, bought this one cheap and am using it to learn on.

The factory shop manual has horrible pictures, and I assumed the lonely mark on the crank was the TDC mark for lining up the cams. Hopefully I didn't bend my valves. Anyway, for the "T" mark that is supposed to be lined up, is it the vertical marking of the "T" that gets lined up, the leading edge of the "T", or the index line just to the right of the "T" ?

I already realigned to the vertical marking of the "T" but it appears that TDC is actually achieved with the mark just to the right. I inserted a rod into the #1 piston and turned the crank by had and that is where I noted the highest movement of the piston.

I'll be checking the compression after I get off work tomorrow morning, I really hope I don't have to replace my valves lol.

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post #7 of 18 Old 05-01-2015, 05:12 PM
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As your investigations have already found [TDC with a rod in the cylinder] it's the index line, not the letter - the letter is a stamp to identify the intention of the line.

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post #8 of 18 Old 05-01-2015, 06:04 PM
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Quote:
Originally Posted by Wolf View Post

Glad someone got the joke. Bad timing?

Another bad joke....

On a serious note, I can't remember if the 919 is an interference design or not.

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post #9 of 18 Old 05-02-2015, 02:41 PM Thread Starter
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It is.

Anybody have some intake valves they don't need? Lol

At least I've learned a bit. Plus my pistons don't show measurable damage.
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post #10 of 18 Old 05-02-2015, 04:56 PM
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Damn, that's a bummer dude.

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post #11 of 18 Old 05-02-2015, 06:11 PM Thread Starter
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Yea, little bummed and a bruised ego, but I'll have another head ready to go Thursday. I'm getting pretty efficient working around this bike.

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post #12 of 18 Old 05-02-2015, 08:31 PM
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It could be worse (yeah, it's me). It happened on the freeway and I babied it home some 3 miles:

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post #13 of 18 Old 05-02-2015, 09:27 PM
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Quote:
Originally Posted by KarlJay View Post
It could be worse (yeah, it's me). It happened on the freeway and I babied it home some 3 miles:
Youch, that was hard to watch.
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post #14 of 18 Old 05-02-2015, 11:22 PM
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OUCH karl. I cringed seeing both bits.

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post #15 of 18 Old 05-03-2015, 01:33 AM
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That was about the 3rd time I rebuilt that engine. Shift fork broke, clutch basket broke, etc..
I have 2 of the 700S bikes and one was for parts... So I swapped the head from my spare parts... Bought new jet kit and K&N filter... ends up the replacement head has an oil leak that looks like the head is cracked.

It's sad because the 700S was a great bike to ride, cool styling, performance, etc... Now she just sits there. The parts are uncommon and it's not so easy to find good used parts.

Good news is that I have some awesome memories on that bike.

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post #16 of 18 Old 05-03-2015, 02:29 AM
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Quote:
Originally Posted by KarlJay View Post
That was about the 3rd time I rebuilt that engine. Shift fork broke, clutch basket broke, etc..
I have 2 of the 700S bikes and one was for parts... So I swapped the head from my spare parts... Bought new jet kit and K&N filter... ends up the replacement head has an oil leak that looks like the head is cracked.

It's sad because the 700S was a great bike to ride, cool styling, performance, etc... Now she just sits there. The parts are uncommon and it's not so easy to find good used parts.

Good news is that I have some awesome memories on that bike.

Dunno where you're looking but there's a bunch of 700s on CA Craigslists for *cheeeeeap* at the moment.

And no, you can't have my spare motor. :P Also, you're aware you can have the head TiG welded so the leak isn't a problem any more, right?

1986 Honda Nighthawk 700S
2002 Honda 919
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post #17 of 18 Old 05-03-2015, 03:05 AM
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Yeah, I had that happen to me as well on the first DOHC motor I ever worked on: thought it was timed properly but was off just enough to bend every last one of the intake valves. From then on I always slowly rotate the motor up to TDC while feeling for any binding at all. It has saved my bacon on several occasions.

Rob

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On the other hand, if it has not been done never assume it is impossible to do it.
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post #18 of 18 Old 05-03-2015, 07:21 AM
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Quote:
Originally Posted by CB700S View Post
Dunno where you're looking but there's a bunch of 700s on CA Craigslists for *cheeeeeap* at the moment.

And no, you can't have my spare motor. :P Also, you're aware you can have the head TiG welded so the leak isn't a problem any more, right?
Awww... I figured if I cry loud enough, you'd send me a completely rebuilt engine

I don't know if you can see it in the video, but there's a huge TIG welder under that bench. I haven't done alum yet, so I'd have to practice a bit.

The real issue is too many things going on right now. I'm retraining myself for iOS app development and with the 919 working well, the 700 had to take a back seat.

I still remember how easy the 700 was to "flick" into a corner, it somehow seemed lighter and nimbler than the 919. I do miss that awesome sound when I'd wind her up, it's one of the best sounding stock exhaust I've heard.

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