Starter turns but engine doesn't catch (also new & old horn not working?)

[Calix]

Old post with problem

Put gas tank back on everythings good but she won't start. Turns, but that's it.

Checked petcock, it leaked about 2tbsps gas straight from the dial before stopping. (20 mins ago hasnt restarted). Check my fuel filter and see that there is very poor flow. (Installed fram inline filter. ) so at this point I'm just thinking I'm not getting flow to the carbs.

Nope, the carb Is leaking from its top left corner ( if behind/siting on the bike) so I'm getting flow.

Did I manage to flood my carb and/or this just a bad seal
I feel the fuel line is too long right now but that's the only way I can fit the filter in there.

(Edit: no leaks now. No vacuum no leak)

Replaced spark plugs with new NGK CR8HSA's, charged battery to full. Shortened main gas line, I know gas is getting to the carbs...still the engine won't "catch" and actually start.

Also, the horns aren't working. I tried to test the original horn but it barely made any noise, like you could hear it opening and closing making just the tiniest part of the noise but that's it. So I went and bought another 12v horn to replace it, thinking the original was just old. But this one does the same thing...odd.

[InvisiBill]

Originally Posted by Calix

Also, the horns aren't working. I tried to test the original horn but it barely made any noise, like you could hear it opening and closing making just the tiniest part of the noise but that's it. So I went and bought another 12v horn to replace it, thinking the original was just old. But this one does the same thing...odd.

Check the voltage at the horn leads. The horn gets power directly from its fuse, and the button completes the circuit to ground. The switch contacts might need cleaning, or there might be an issue elsewhere in the circuit.

[NGagne]

Sound like Electric trouble, Are you sure that the Plug make Sparks??

[Calix]

Originally Posted by NGagne

Sound like Electric trouble, Are you sure that the Plug make Sparks??

Seeing all the electrical problems I have had I wouldnt doubt it. Going to check horn leads and pull plugs and check.

[Calix]

Checked plugs, no spark. It seem from the multi-meter readings that 11-12 volts is being supplied to the coils. So guess its time to buy some new ones. Hopefully this is my last problem

[Ghostt]

Even bad plugs should do something, unless they are totally shot.

Did you renew the HT leads, and disassemble the caps?

Make sure you disassemble the caps, and clean them, and yes the caps get cruddy.

Here my write-up,

Short explanation: The inside of the hard plastic caps accumulate crud the can short out the spark. This can cause rough running or failure to start. Every time you do any work on the bike: remove them disassemble and clean them and renew the wires or at least the connections.

The long Explanation, Warning engineering information can cause Drowsiness.
The ancient cylinder design of the engine dictates that the spark emanate form the center of the combustion chamber. In order to get it there, the plugs had to be located down deep in a well between the cams. This well is a perfect place for dirt and moisture to accumulate. Then because there is no cooling water at this point the metal around the plug runs very hot. Surround this with the large amount of cool metal and you have a recipe for condensation. Now K did drill a drain hole between the fins to help (a little) but it often gets plugged up.

The moisture boils off the base of the plug and the vapor condenses on the cool plastic cap and the plug insulator. This moisture forms a easier path for the electrons to ground than jumping the gap at the plug to make a spark. Misfire.
This issue is right up there with Pilot jets as a cause of trouble.

Here's some pictures that might be helpful. I took these when I replaced the wires themselves, as it was a good time for a write-up, and the wires were OEM from 1998.

Wires are just 7mm copper core, with clear silicone jacket




















NGK Iridium IX® plugs are the way to go personally, I run them in both the Ninjette and EX.
http://www.ngksparkplugs.com/product.../iridiumix.asp

NGK (7669) CR8HIX Iridium IX Spark Plug, Pack of 1 https://www.amazon.com/dp/B000HDF852..._3P6Zvb2PBX9FX




You need three things for the engine to run, fuel, spark, air, all in the right amounts, and timing.

An engine is just an air pump when you break it down to the basics.

Sounds like your petcock might be bad? How did you clean the carburetors?

[Calix]

Carbs were completely dismantled and every piece inside and out was soaked in carb cleaner for 2 days. Being scrubbed down about 4 times a day will soaking. They are pretty darn clean now. All the jets and needles were cleared with an air compressor. And everything was dried and double checked before reasembly. I made sure both tuning screws were out 2 1/2 turns (I believe it was 2 1/2 it was whatever was suggested) and that the paths for all the needles/jets/ etc were cleared.

[Ghostt]

Originally Posted by Calix

Carbs were completely dismantled and every piece inside and out was soaked in carb cleaner for 2 days. Being scrubbed down about 4 times a day will soaking. They are pretty darn clean now. All the jets and needles were cleared with an air compressor. And everything was dried and double checked before reasembly. I made sure both tuning screws were out 2 1/2 turns (I believe it was 2 1/2 it was whatever was suggested) and that the paths for all the needles/jets/ etc were cleared.

Verify that the float height is correct? Were the plugs wet with gas? Did the float needle valves replaced? Inspected?

[Calix]

Nope not wet with gas, floats were intact and moved freely. Needle moved freely as well and moved in conjunction with the floats.

[Ghostt]

Originally Posted by Calix

Nope not wet with gas, floats were intact and moved freely. Needle moved freely as well and moved in conjunction with the floats.

So no gas getting to the engine? Then check vacuum petcock for proper operation.

[Calix]

Ahh, I haven't taken the carb apart since first getting the bike. Honestly its not something I look forward to doing again. I'm about sure that fuel is reaching the carbs. It was overflowing from the overflow tube. It just wasn't being ignited due to the spark plugs not sparking at all.

[Ghostt]

Originally Posted by Calix

Ahh, I haven't taken the carb apart since first getting the bike. Honestly its not something I look forward to doing again. I'm about sure that fuel is reaching the carbs. It was overflowing from the overflow tube. It just wasn't being ignited due to the spark plugs not sparking at all.

If you have gas coming out the overflow, you have problems,

At this point I'm going to suggest getting in touch with @ducatiman for all your carburetor needs, PM him.

https://www.ninjette.org/forums/showthread.php?t=226815

https://www.ninjette.org/forums/show...wpost&t=239678

His services are very affordable.

[Calix]

Thanks for the recommendation! I think you may have linked him before. But that thread you just posted was what tipped me. I will shoot him a PM in the PM

You are quite the night owl ghost. But, I guess it's fitting.

P.S you think he would paint my carbs a nice kawi green? I'm looking to repaint her in a kawi green/ black metallic flake color scheme.

[Ghostt]

Originally Posted by Calix

Thanks for the recommendation! I think you may have linked him before. But that thread you just posted was what tipped me. I will shoot him a PM in the PM

You are quite the night owl ghost. But, I guess it's fitting.

P.S you think he would paint my carbs a nice kawi green? I'm looking to repaint her in a kawi green/ black metallic flake color scheme.

I'm always around somewhere

As far as painting goes, let your imagination run wild.

@ducatiman is well know and respected over on EX-500.com, and I suggested to him to try here, he's done a few members here with excellent results. I personally vouch for him and his services.

[ducatiman]

night owls ...up way too late for me.

Calix..red, blue, yellow...why not green? Can do.

Hey, how 'bout different color for each body? That would be something new and distinct.
Or bowls and bodies of separate colors.

As Scott said...let your imagination run amok.