1150 ADV Rough as arses after new battery

[Robster]

Before we start, yes I have checked, re-checked, checked, re-checked and checked again that the throttle cables are seated correctly!

OK, so I did a basic service on the 1150 ADV on Sunday. Dropped and changed the Engine, Gearbox and Final Drive oils. New oils, oil filter and spark plugs went in.

A quick test fire after that revealed she was running nicely and a little more smoothly as the old plugs were a bit grotty.


Next job was to install a new Motobatt battery and, whilst I was in there, I swapped out the manky old K&N air filter for a regular paper one until such time as I clean up the K&N. Tank went back on, breathers and fuel hoses were re-connected (and QD's "clicked"), electrical block re-connected and tank bolt back in.


Another quick test fire revealed all was not well. She now struggled to start at all and would only fire up with a handful of throttle. Then, when she was finally running (and obviously I didn't run her for long with these symptoms), she wouldn't idle without throttle and ran rough as arses – all symptoms that would immediately point anyone towards the throttle cables being out of position but I've checked and re-checked so many times now I can't remember. I didn't whack the TPS out of position whilst I was fiddling and I've now had the tank on and off 4 or 5 times to check for anything obvious and stupid I may have done under there but I just can't see anything!

I guess the symptoms are also worryingly very very similarly to when she burnt out an exhaust valve a couple of years back. Seems like the worst possible luck that a valve would go between one fire up and the next a few hours later – it didn't take me that long to swap the battery and filter, I went and had my dinner in between, honest!

I'm at a bit of a loss now. Next job was to install the upgraded cam chain tensioner doobry and adjust the valves but I'm loathe to go any further until this particular issue is ironed out.

What have I missed?!

 

[Greg Masters]

Have you tried reinstalling the manky old K&N filter?

Have you checked that there's no kink in the fuel lines?

Is there extract of anus on the wiring block?

 

[DrAlf]

How are your QD's configured? Is it possible to connect them the wrong way round?

 

[Slipperyeel]

Just thinking out aloud but is it possible one of the HT leads wasn't pushed home and on the second firing has come off? (You didn't mention if it was single or twin Spark)

 

[doyle]

Seems either a fuel or air shortage,

 

[Slipperyeel]

Why not possibly ignition?

 

[Robster]

Thanks all for the input – I don't think the fuel lines are kinked, would be bad luck to kink/pinch them all 5 times I've had the tank on and off though I will check again!

It's a Twin Spark, so yes it's possible one of the lower leads has come adrift - I'll check those too.

QD's are set up in opposing directions so they're definitely hooked up the right way around... that was the second thing I checked after the throttle cable seating!

Haven't tried slotting the old K&N filter back in, not sure what that will achieve really but yes, worth a go in terms of eliminating things that've changed and narrowing the problem down I guess.

 

[monkeyboy]

Sounds like ignition to me too. It will run with the TPS disconnected - you can even ride it like that... carefully:: so I doubt it's that. QDs can only go back one way. I very much doubt the air filter will make any difference but worth a try.

You've checked the cables but I would just flick both the throttle body cams with your fingers and confirm they click against the stops when you do in case they cable is out somewhere else.

In fact.... thinking about it... I had something a lot like this.... When I'd been messing about, one of the cable sleeves came out the balance box. It looked like the cables were ok but looking at the throttle positions against the stops, one was open because the sleeve was out the balance box and was effectively opening the throttle on that side. You should be able to see if that's the case - ie look how far the throttle is off the stop

Good luck anyway

 

[Fanum]

You're supposed to take the paper air filter out of its box before you put it in

(AKA check you didn't leaved that rag that you wiped the inside of the airbox out with inside there, check nothing fell into the box etc)

 

[Greg Masters]

Factory fitted QDs can only go back one way.

Fixed.

Early 1150s didn't have QDs and many were retrofitted by the able and less able

 

[fizzer]

yes mine was running fine till i changed the plugs ,the fault was a coil pack ,obviously when i pulled the coils of i disturbed something .so maybe you have a coil pack on the blink .and nowt to do with you having the tank of.

 

[monkeyboy]

Fixed.

Early 1150s didn't have QDs and many were retrofitted by the able and less able

Didn't know that His is a twin spark so will have as OE.

 

[Robster]

More good suggestions, thanks!

yes mine was running fine till i changed the plugs ,the fault was a coil pack ,obviously when i pulled the coils of i disturbed something .so maybe you have a coil pack on the blink .and nowt to do with you having the tank of.

Yeah, definitely worth checking, although I did fire her up after I'd changed the plugs and before I pulled the tank off and she ran fine. One more thing to cross off the list though

 

[Flipfly]

Had a similar problem with mine, turned out to be the pipe from the fuel pump had blown off because whoever replaced the fuel filter reused the BM clips and they were loose. It happened when I hadn't quite clicked a connector fully home ( well my mates lad hadn't ).

There's no way you could have snagged a cable coming out of the junction box and dislodged it at the other end? People normally only check the throttle bodies, but I assume it's also possible to do something similar at the junction box

 

[monkeyboy]

Had a similar problem with mine, turned out to be the pipe from the fuel pump had blown off because whoever replaced the fuel filter reused the BM clips and they were loose. It happened when I hadn't quite clicked a connector fully home ( well my mates lad hadn't ).

There's no way you could have snagged a cable coming out of the junction box and dislodged it at the other end? People normally only check the throttle bodies, but I assume it's also possible to do something similar at the junction box

That's exactly what I said above Easily done too. The little rubber detents that stop the cable sheaths coming out the junction box are rubbish and snap very easily. One side is easier than the other to relocate but it's only a 15 minute job anyway

 

[MikeO]

Are both your balance pipe covers still in place?

Part 14 in this diagram

 

[Flipfly]

Sorry, so you did

Answers my question though, it is indeed possible

 

[DrFarkoff]

Before we start, yes I have checked, re-checked, checked, re-checked and checked again that the throttle cables are seated correctly!

At all 4 ends??????

Reason being Doing a bit of a Sherlock the only thing you did after service was to take the tank off and on

Symptoms you describe are perfect for cable problem

So The real way to check the cables are seated is to look at the back and make sure the cable quadrants are hitting the stops

 

[bowser]

I had a very similar problem, in the end a change of fuel filter in the tank fixed the fault, god knows why it became a problem just taking tank on and off but it did

 

[Robster]

Thanks guys - it definitely sounds like a cable problem, the symptoms are identical to a dislodged cable at the throttle end, so it's entirely possible (and hopefully likely) that it's popped out at t'other end.

The little rubber cap on the TB is also a good (and nice and easy) thing to check.

Good tip re the pipe "blowing off" (snigger) inside the tank - if all else fails I'll have a squizz at that too.


Worked late last night so didn't get a chance to have a poke around, but all that info gives me a good few things to investigate this evening.

Now...where exactly do I find/how do I get to that throttle cable junction box?! Can't say I've ever noticed it - anyone got a pic or a diagram handy?