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Discussion Starter #1
I have spent the better part of the past 2 days doing the 24k mile service on my 2000 LT. I put on new throttle cables. (They are freaking awesome! If you still have the old style cables you owe it to your self to upgrade to the newer cables.) I bled the brakes and clutch. Changed out the coolant. Installed a new fuel filter. Installed a new K&N air filter. Changed the motor oil, final drive and trans oil. All of that was pretty easy (just time consuming).

Then I decided to tackle a valve check. I used the instructions posted here: http://www.gunsmoke.com/motorcycling/k1200rs/valves/index.html

I did leave the spark plugs installed per the manual.

I told myself that I was just going to check the valves. If there were any that needed adjusted I WAS going to take it to the dealer. Well, I found 2 intake valves that were just a hair tight. I figured that everything else had gone so well I could tackle pulling the intake cam and doing the job myself. So, I followed the instructions as described. I used a #30 drill bit to use as my cam tensioner tool. I got that in ok. Then I stopped cylinder #1 90deg from TDC. I put a couple zip ties on the intake sproket and another zip tie on the exhaust sproket for good measure. I pulled the intake cam with no problems.

I think I got the everything put back together correctly too. I put the intake cam back in place. I put the thrust bearing caps in exactly the same place they came from. I tightened the 4 caps from the inside out and then torqued them to spec. I left the cam bearing cap finger tight. I turned the cam with a 19mm wrench until the slot in the cam lined up with the pin on the sprocket and it just slid into place. I tightened the bolt that holds the sprocket to the cam and the bearing cap.

I rechecked all the clearances and buttoned it up. I also put in new plugs after I finished. So, I get the bike put back together and start it up. It was running like crap and making a lot of "scary" noises that I wasn't too crazy about. I thought it might be a little starved for fuel because of the new fuel filter, but after running for about 5 minutes it hasn't really improved. Anybody have any ideas? I was wondering if I may have missed plugging in a sensor somewhere alone the way with all the reassembly that I had to do. Just don't tell me I botched the valve job. I don't think my wallet can handle that... :(
 

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Try turning on your ignition, fully twist the throttle 2 times slowly, turn off the ignition then turn on & start the bike, this has happened to me before & this remedied it.
When you disconnect the battery you need to reset things, twisting the throttle basicallly does this, although i dont recall the horrible noises, just a bit of rough running & a fast idle till the brain took on the new settings.
Regards
Stevie
PS, sure someone will chip in with the correct technical terms & details!.
 

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SpudRider...

Don't panic yet...

Give us more details...

Bike year

How far did you take it down? Replace fuel filter, etc?

It could be something simple like plug not fully seated.... or carbon popped loose onto a plug, etc...

Are noises chain related?

Maybe someone in your area with experience could pop in to have a look/listen?
 

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Yep, I like Stevie's recommendation. When you're thru with the TPS (throttle position sensor) dance, take the scoot around the block a coupla times while the Motronic settles in on re-establishing the parameters. Then, you should be good to go wherever you wanna. Good luck.

If thangs don't quiet down, then Chann's suggestions merit a look. And hopefully, the fix will be easy.
 

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Discussion Starter #5
The Basics:
2000 K1200LTC
23k miles (I know. I got it last year with 14k on the clock. It's not my fault.)
New fuel filter
New plugs
I live in Boise, ID

OK. I disconnected the battery and let it sit for a minute, and then I tried to reset the TPS per the comments above. On the bright side most of the "scary" noises are gone. After reading a little more last night I hope the noises were just the cam chain tensioner doing its thing. I ran it around for about 5 miles, but this hasn't solved the issue.

It surges when riding, and there seems to be 25% of the power I'm used to. It does seems to be fairly vibration free. Also, I'm smelling gasoline. I don't think that I'm banging away on all cylinders...

Thanks for the help.
 

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Is the charcoal canister still installed.................?.........And if you crack the gas cap, is there a little vacuum...............?....... :eek:
 

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Discussion Starter #8
OK. I just thought that I'd check the spark plugs. I pulled them all and it looks like cylinder 2 and 3 aren't working.the plugs look brand new. I put old plugs in 2 & 3 and it still runs like crap. The gas tank doesn't seem to have any vacuum. The charcoal canister is still installed, and I'm pretty sure that I hooked up the gas tank vents properly.

Thanks for the help.

I'm headed back to the garage...
 

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Discussion Starter #9
cfell said:
Yup.. and are you sure you hooked up the vent lines correctly? If you swap them it can run awful.

Can the cannister.

There are only vents on the tank, right? There is a vent line and another line on the "rubber thing" by the filler, right? I didn't unhook the line on the rubber thing, so I'm pretty sure they are right.

When I replaced the throttle cables I didn't remove the fuel rail or the throttle bodies. I was able to get the job done with some looong forceps and a little patience. I did have to unhook a couple, what I thought were vacuum lines. I think I got everything hooked up correctly, but could this be my problem?
 

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2005 K1200LT
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OK I gotta ask... Did you pull the pin from cam chain tensioner?
 

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it is possible you are not getting spark at the failing cylinders... the wire could be bad... the coil wire to plug or one of the control wires going to the coil...

Time for a patient, careful look at what you did..

One thing you can do is spray wd40 around the vent / hose lines by the motor.. if engine speed changes, you have a leak.
 

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Discussion Starter #12
Fixed it!!! :)

I manged to move the injector rail when I put the new throttle cables in. 2 injectors came out of their holes. Pulled everything off and got it fixed. I just finished buttoning it up. Runs like a champ. I'll enjoy my ride to work in the morning!!

Thanks everyone that took time to help me out.

Lesson learned. Make sure that everything works perfectly before you put the tuperware back on.
 

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I just got mine back and its a world of difference.
Jim
 
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