New toy (TZR421) is on its way!!!

[Jeram]

Well, 2 defective ignitechs in a row!

once bitten, twice shy, three times and Im now frothing at the mouth with frustration.

everything works with the exception of one thing. the ignitition only performs one funtion before shitting itself and requiring a reboot!

it will give me one spark, or one tacho output then it looses connection with the PC and wont respond until I kill the power and then reconnect it.


Luckily for now I've got a spare base model igntech (the first faulty one which did everything except control servo motors!)
So Ill butcher that one off the poor neglected CRM for now to get this bike running this weekend.

I can only recommend that in the future people use zeeltronics. anything else is just a $500 bet in a game of Russian roulette

[fred99999au]

drop on round if the rego is good. Unfortunately, I wont be riding with you, as I broke the end off my right fibula last Sunday, so not much riding in the very near future for me.

Not terribly cheery about that one.

[Aussie_carbon]

zeeltronics have always been well proven in my books, i brought one of the first programmable ignitions for the rs when it came out, simple to use with the pv controller aswell.

[hybrid]

How have you got it connected to the PC?
Are you using a USB to serial converter?

If so, some of them can be very flakey. I use them to tune my megasquirt ECU and have found a decent brand one now that is pretty solid.

[Jeram]

yeah not that, I've been programming with this one for a few years now without any dramas.

even without the PC connected to the CDI, the ignition still crashes after the first spark event.

I fitted my spare ignitech from my CRM and it instantly started working. I've got a decent spark on both cylinders now

I just need to buy some new spark plugs and some fresh fuel for the bike and then I can hopefully get her fired up again.

[hybrid]

No worries.

[fred99999au]

What plugs do you need? I have some BR9EIX (I think) here if I can find them. Suitable for the RZ anyway.

[Jeram]

Sounds perfect mate, perhaps il come over this arvo to return previously borrowed items and steal those plugs off ya (il order you some more online)

Then il pop up to the servo to get a small Jerry can of fuel.

Fingers crossed ill be going for a ride on her this week

[Jeram]

I got her running finally after days of trying to start the bike and having it kick back on the starter lever like a CR500 with some loud pops and crackles
After a quick chat with Lozza (2Ti) we worked out that it must be the ignition programming so we switched the polarity of the flywheel pickups and one kick later she fired to life, sounding much angrier than she has sounded previously.
The coupled with going down 1 pilot jet, down 1 main jet, she starts easily, idles well and revs out clean.

Now I just have to swap the batteries over next weekend to a lithium ion battery, swap the thermostat over for a lower temp one (Im assuming the FZR thermostat is 100 degs!)
then I can strap on the go-pro and take her for a ride!

if she goes as well as she sounds it will be very fun indeed!

[Jeram]

well, today went well and disastrous.

I took the bike for a ride and it was fucking fun... but after 15 mins the clutch rod adjuster nut came loose and cause the rod to go to full adjustment causing the pressure plate to grind against the clutch cover, cracking it and mutilating the clutch rods.
all thanks to the previous owner not torquing the nut up properly.

damage bill in only 100 or so bucks but its mainly just disappointing.

[Jeram]

I ended up dropping the motor out of the frame and splitting the cases today as the clutch rod was mushroomed at one end and had the bearing welded to it at the other so there was no way known it was coming out.

engine looks perfect on the inside


damaged clutch rod


scratched clutch pressure plate


welded ball


welded/damaged actuator arm


bent clutch adjuster which fully wound out of adjustment when the lock nut came loose, causing the carnage.


And the cracked clutch cover which I couldnt get a decent picture of.


I should have all the bits before christmas but will have to have a good think about whether I want to do any other work on the engine while its out such as new rings (130psi comp with 20cc head is pretty bad). and perhaps radius the roof of the exh port so it doesnt eat rings in future.

[L.B.]

What about Wicked's fancy clutch bearing replacement?
Never seen the cases split that way before,dropping the whole shebang into the top case,would be easier.

[Jeram]

Yeah it's very very easy I'm liking these vertical split cases a lot!

[Jeram]

spoken to a few people in the know and the 20cc domes are fine for pump gas (yet again the banshee forums are bull of bullshit artists), and the comp guage reading should be taken as a grain of salt.

I've done the calculations and a 68x58mm cylinder with a 20cc head dome will develop 154 static PSI (in a perfect simulation without any losses including no allowance for gases lost from the 28mm high exhaust port)...

So 130psi is great.

Ill save the exh port modifications untill I actually have to change the rings in the future as Im keen to find out how long the rings will last as-is.

[JonW]

Sad to see that damage, but yea as Jase says fit the ball upgrade sold by Wicked, it will avoid this kind of issue.

As you said I would leave the rings etc for now, just refit the clutch pusher parts and go enjoy