"sudden" rough running...

[Lion_Lady]

Okay. Maybe not sudden, but it kind of seemed like it. Bike is approaching 60K miles. In need of general 60K service...

Last year, the bike ran like a tractor... broken spark plug connector. Replaced that. All was well. I have not yet replaced stick coils (I bought two anticipating that was the problem, then returned them both). Prior to that, hubby had the bike apart to replace the rear transmission output seal (see guitardad's thread). Bike has run fine since that.

But about two weeks ago, I realized the bike has been harder to start - 6 year old battery. Got stuck at work yesterday, even with a "jump" - extra oomph from a car battery, the bike would turnover, but not catch. Thought I'd flooded it, but no gas smell. Would catch, putt putt, then die.

Replaced battery last night. Still no joy. Right upper spark plug is fouled, bike runs like cr@p with that upper plug wire disconnected - so don't think its the replaced connector. And I haven't checked the other plugs. I'm getting new plugs today, but looking for any other trouble shooting help folks can give me, beyond "do the 60k service." I'm planning to do a TB sync and valve adjust tonight, oil change, etc. Oh. And I need to be able to ride the bike this weekend! Hubby is heading out on Thurs for the Cape Fear 1000 Rally, and I'm riding down on Friday to assist at "base camp" so I'm hoping that there is something that this total neophyte can do with little technical guidance.

Thanks!

P

[timl]

I too experienced "sudden rough running" about two weeks ago on my '04 Rockster (37k miles). Rode into work and it ran perfectly smooth like it always has. Later that day on the way home I encountered some traffic which took awhile to clear. I immediately noticed that it was not running well - very rough under 3000rpm and the idle was down under 900rpm.

It has continued to run that way since. I replaced all 4 plugs (they looked normal although one of the secondaries was well carboned up) and that helped only a little. It does not like to run below 3000rpm; it runs well under load and accelerates well, but cruising at 3000rpm thru my neighborhood it surges, misses and backfires. Very rough idle - I have to give it a little throttle to avoid a stall.

Based on all the symptoms I read on this and other sites, I went ahead and ordered new stick coils which I'm hoping will fix.

Regarding your issue, its not clear what the symptoms are. It sounds like you are able to get it running now with the new battery. Can you describe the "runs like crap"?

[Trompie]

I don’t know if this will help but also look at the throttle cables, on mine the right side jumped out off the little cup and was resting on the edge. The bike did not want to start and when it did, I had to keep it at high revs. I only noticed it after a long ride with a lot of swearing.

[boxermania]

Aside from Trompie's post regarding the throttle cable riding outside of the holder (that typically will make the bike very, very hard to start) the general symptoms and the mileage do point to intermittent or failed stick coils.

Search for stick coil testing.....do install a new set of plugs as well.

[spoon]

I would also check the vacuum lines on the bottom of the TB's, and the rest of the vacuum lines if you have not done the canisterectomy.

[Lion_Lady]

Figured it out... all 4 plugs were fouled. I'd been parking near the door at work prior to opening, then moving the bike - ie riding it - the 200 yards to the "employee parking"after we open. Running the bike just long enough to start to get oil flowing, but not enough to get the engine warmed up.

Did a valve adjustment, and TB sync. One side was a bit off. Also a compression test. That was good. Replaced the plugs, all is well. Thanks! Running much better, though the bars are a bit "buzzy" in my hands now. Something needs tweaking. But that can be taken care of after the Cape Fear 1000 Rally.

P

[Kobe22]

Hey LionLady,

Mine cut off in traffic and hasn't 'resurrected' since (last week Thursday on 495 N)... don't know what to do....

All i did was put in some rush hour commuting...

But I'll explore the spark plugs and see where that goes...

[omg1010]

This could have many reasons (apart of the throttle cable ...). Suggest you check that the fuel supply is OK. Secondly check the spark. If both are fine it means the fuel pump is fine and the ignition coils/spark-plugs as well. Then it maybe the hall sensor ...

Brgds
Oliver