NY-LONG ISLAND service - Page 13 - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #301 of 320 (permalink) Old 8-8-2019, 9:05 PM Thread Starter
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Agreed basic stator is sound...even with insulation break, static bench testing is perfect.

Owner and I are in agreement on a total Shindengen Mosfet RR conversion. I've got a couple here...the older FH010 from ZX1000. I've got proper wire, sheathing, Furukawa connectors.....everything to convert. I'll attach my larger wires at stator, full run right to RR.

I want to relocate to the LH side of bike nearby stator, short wiring run, compact and neat run and fab. The RH requires a long run harness fabrication.

I did mock-ups on both sides....pics sent to owner...I vote LH side...awaiting his thoughts. We're contemplating overnight.

Note the bike was received without an RR attached....anywhere! MIA.

Don't want to jinx, but we are *so* close to wrapping it up. Test ride owner reported its pretty darn fast. Thankfully steering straight, suspension feeling good.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #302 of 320 (permalink) Old 8-8-2019, 10:51 PM
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Really looking forward to seeing how this turns out!!....sean


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post #303 of 320 (permalink) Old 8-10-2019, 1:05 PM Thread Starter
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the Pile still fighting in every conceivable aspect.

Stator repaired and installed (both static and running output testing perfect)
"As is" prior owner wiring and using current owner supplied Ricks regulator....I'm getting idle hunting and ignition missing at no throttle opening. Unplug RR ....better but not perfect.. Plug in RR...hunting/missing.

I'm rigging up a test harness for the Shindengen. However...meanwhile I'm highly skeptical of the existing wiring platform as the Prior owners were hacking and chopping everything/everywhere. Very possible they got deep into this harness. An unknown, can't prove but at the same time...can't dismiss the aspect of a poor connection inside the harness caused by the electrical geniuses. Maybe a wirenut came loose.

Testing using a known good Shindengen, totally bypassing the harness will ensue this afternoon.

Additional...I did a no-no, running the bike without RR (running ok) ....then purposely plugging the Ricks RR in while running ....the damn thing returned to a perfect idle....no missing. The stator output wires (which run through the harness) getting hot, I then shut it off.

So the thing chose to run ok! The Pile now throwing an apparent intermittent electrical quotient into the mix. Intermittent electrical can be real nasty to pinpoint. So RR, harness both suspects.


My Shindengen temporary test harness will bypass the existing harness. We shall see. After this, I'd never own a Triumph...ever.
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post #304 of 320 (permalink) Old 8-10-2019, 5:11 PM
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Quote:
Originally Posted by ducatiman View Post

. An unknown, can't prove but at the same time...can't dismiss the aspect of a poor connection inside the harness caused by the electrical geniuses. Maybe a wirenut came loose.

My Shindengen temporary test harness will bypass the existing harness. We shall see. After this, I'd never own a Triumph...ever.
Gah....what a mess. Sounds like a short or open hidden inside the harness. Soooo difficult to pin point, specially after "geniuses" got in and ratted it all up. Hope your close to sorting that mess......sean


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post #305 of 320 (permalink) Old 8-12-2019, 7:14 PM Thread Starter
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The temporary test harness using a Shindengen did the trick, no hunting, steady idle again.
Obvious wiring issue...no need to get over analytical......a full stator rewire end to end will ensue, using the good stuff.
We're gonna do one more, final TuneECU session followed by a testride and long overdue bodywork reattachment.

It ain't over yet....this thing historically throws some nasty curveballs.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #306 of 320 (permalink) Old 8-12-2019, 10:41 PM
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My Shindengen temporary test harness will bypass the existing harness. We shall see. After this, I'd never own a Triumph...ever.
Don't blame the bike. The ham-fisted butcher who inflicted the damage is 100% at fault here.

I've had a few (modern) Triumphs now, and they have been amazing in all aspects. Had more trouble from my Honda's.

At this point I'd keep my eye on eBay for a complete replacement harness....

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post #307 of 320 (permalink) Old 8-13-2019, 9:26 AM Thread Starter
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I know, just venting. I believe I've got the issue and repair path isolated.

Fact- PO's centered their electrical "efforts" around bling bling lighting, electrically hacking yet *thankfully avoiding* sensors and the throttle bodies/engine area

Fact- PO's hotwired the cooling fan to constant "ON" (what a mess made there, but bike came from Texas hot environment, could at least explain their motive)

Fact-*12 codes* present and documented when this bike received...all corrected/cleared

Fact- bike received without the presence of a Voltage Regulator...being upgraded/corrected

Surmising on my part...
PO's opted running without VR due to hunting condition (which they were unable to diagnose and correct)
PO's had no regard for the ML (maintenance light) whatsoever (likely beyond their numb capacities)
Po's riding bike close to home only (at total loss due to no VR) or ridden little, if at all. Was this bike a bling/electrical play toy for immature kids only?

Now very close to 100%...saved, brought back from "the Pile".....I believe this thing will (yet again) be quite a potent little streetbike.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #308 of 320 (permalink) Old 8-13-2019, 5:41 PM
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Good job!!!

You know... Lucas probably had a hand in Triumph's electronics...
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post #309 of 320 (permalink) Old 8-13-2019, 7:07 PM
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Quote:
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Good job!!!

You know... Lucas probably had a hand in Triumph's electronics...
You know the old joke;
"Why do the British drink warm beer?"
"They have Lucas refrigerators".

My apologies guys. I just couldn't resist that one
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post #310 of 320 (permalink) Old 8-14-2019, 8:18 PM Thread Starter
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I do believe this thing is wrapping up after a good days work today. Rewired the stator full run to the RR culminating in....no hunting or erratic running! Nice steady idle and instant throttle response! Meanwhile, charging system fully operational.

One more TuneECU session to double check, verify no hidden electronics issues.
Followed by an extensive test ride by owner.
Followed by bodywork/fairing installations and this baby is done. Finally.

Pics'll follow when fairings are installed (and some tasteless decals are removed).

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; 8-14-2019 at 8:21 PM.
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post #311 of 320 (permalink) Old 8-14-2019, 9:02 PM
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Given the history of this project, I'll be holding my breath until final testing is completed
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post #312 of 320 (permalink) Old 8-14-2019, 10:49 PM Thread Starter
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Ha! Agreed this thing has thrown some tricky curveballs, but I believe we're finally reaching some consistency (sigh of relief)

We've eliminated so much... on earlier test rides gearbox, suspension, tires, brakes, drivetrain ok. Trouble codes eliminated, electrically related functions restored, all known PO hacks finally reversed, charge system confirmed now operational.

All lighting has previously been repaired/confirmed with exception of nose fairing mounted headlights which I'll check in the morning.

Really not much left (fingers crossed) but bodywork.

This thing was *gone* upon receipt ....I can now proclaim in all reality....a rescue

pic full rewire at stator point of origin
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Last edited by ducatiman; 8-15-2019 at 7:42 AM.
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post #313 of 320 (permalink) Old 8-15-2019, 4:51 PM
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More like resurrection!!! What amazing work!
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post #314 of 320 (permalink) Old 8-17-2019, 9:40 AM Thread Starter
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An interesting learning experience on "the Pile" yesterday....another long marathon.

Further test ride revealed we had somehow regained mildly erratic running under barely cracked open throttle ...researching a post on a 675 Triumph forum related to a guy with exact circumstances as ours...the nearby crank position sensor tested perfectly to FSM ohm readings, no damage, but precisely the same partial throttle fault. He replaced the CPS regardless...as we did yesterday....with a return to perfect throttle response.

These modern electronics perplex me, the replaced unit threw no codes, revealed no visible damage and ohm tested dead on equal to book values, but was somehow faulty. I don't understand how the book testing process can no longer be trusted, relying on a "dumb swap".

Regardless....the Triumph now running *perfectly* with a RH fairing panel now installed!

Oh, of course we had repaired/checked everything but headlights....after mocking up the nose fairing....a GREAT BIG FAIL. NO headlight, high or low. I'll be on that today. Another freaking curveball..... @K-woppa predicted it!

The owner did an extensive 2nd test ride and was really impressed with both running and handling!

Now down to headlight repair and final fairing installations! Also some tasteless decal removal required on the fairings.

Again, pics will follow when actually *done*. This thing gonna run and look pretty darn nice.

Reconsidering....the "Pile" could have alternately been named "Curveball"....or "Relentless"...all befitting.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #315 of 320 (permalink) Old 8-17-2019, 9:31 PM Thread Starter
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Lights operational!

Imagine a 4 pin relay plugged into a 5 pin socket and ....the opposite. Yup, the numbnut PO's switched relays in their intended sockets. Somehow makes sense....dunnit?

Anyways....we are down to final fairing install....I'll assist the owner in doing so.

My main work is now done....

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #316 of 320 (permalink) Old 8-17-2019, 10:26 PM Thread Starter
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I'm surmising...wondering if all the PO hacking/wiring wacky efforts were desperately motivated by powering of the headlights....all due their inability to diagnose the switched relays....choosing to sloppily cut, hotwire, steal power from other hot wires instead. Wow.

The mess was well documented, I always found the motive perplexing. Why would anyone do something like this to a bike?

In encountering the lighting issue and solution....I now believe their inability to diagnose and restore proper lighting function drove them to such drastic, unprofessional measures (I'm being very nice here) in their efforts to get the headlights working.

Tracing the headlight power source lead me to relay group...output voltage testing (none present) careful examination and component comparison using wiring diagram revealed the installation error....about 30-45 minutes total had it wrapped. A genuine "lightbulb" moment (ouch, sorry )
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“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #317 of 320 (permalink) Old Yesterday, 1:17 AM
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Detective work is fun, innit? Glad you got that sorted finally. I agree with your surmised reason for the hacking. Logical thought process that.


Sounds like you need a beer .....sean


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post #318 of 320 (permalink) Old Yesterday, 7:24 AM Thread Starter
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I *deserve* a beer....and more, though I'm being amply "taken care of" on this. We had a POP (pay one price) agreed upon my receipt of the bike....whatever it takes, whatever ancillary crap I need to supply. In this case included tie wraps, electrical quick connects, ton of solder, wire, desolder braid, various 6-8mm nuts, bolts, washers, oil recycling, use of any and all of my tools, test equipment, stands, on and on.

Basically, the bike (and all its associated headaches) became mine to restore to working order. Even with the owners assists, I've probably got well over 100 hours in on this project. No complaints..."whatever it takes" was the motto.

Always an interesting, challenging learning experience...like the "Gomers" carbs...you never know what you'll encounter inside. The owner commented he learned a ton working with and assisting me, he knows his bike inside and out.

All is good now in Triumph land.

A Ducati Monster due next....a major service, carb clean, valve adjust, belts, sp plugs, air/fuel filter, and anything else associated. Here we go again? No, this thing a runner, owner just purchased, neglected and simply needs a thorough, "new to me" full service.

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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post #319 of 320 (permalink) Old Yesterday, 12:17 PM
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A Ducati Monster due next....a major service, carb clean, valve adjust, belts, sp plugs, air/fuel filter, and anything else associated. Here we go again? No, this thing a runner, owner just purchased, neglected and simply needs a thorough, "new to me" full service.
Yeah....but it's a Ducati..!! My 996 is getting a "new to me" service over the Winter....Yuk, there's the 'W' word already. The VFR is also getting a well deserved strip & rebuild from the frame up this Winter. Gonna be busy getting ready for Spring.

Great job on the Triumph. Another pound case hits the road.

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post #320 of 320 (permalink) Old Yesterday, 7:34 PM Thread Starter
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A 6 month project...the formerly mangled Triumph 675 completed today in a co effort session with owner. Bodywork properly mounted incorporating (previously missing) factory components, we actually did cleaning and detailing. Visually, I think it turned out pretty darn nice.

Running AWESOME, no codes, every function now operational. All PO hacks repaired/reversed.

It's ready for New York State inspection (and should pass)

We are both impressed with the final product....an astounding transition. I have 1 more visual trick I'll do tomorrow, standby on that one.

The lineup in my garage tonight (if its red its mine)
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File Type: jpg tr6.jpg (145.6 KB, 3 views)
File Type: jpg tr7.jpg (143.0 KB, 3 views)

“Being shot out of a cannon will always be better than being squeezed out of a tube. That is why God made fast motorcycles, Bubba....” quote Hunter S Thompson

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Last edited by ducatiman; Yesterday at 8:39 PM.
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