Hesitation at 2000 rpm, 100% throttle

[Pete]

My bike has been tuned three times on the dyno by local Brisbane tuner recommended by Nev Lush.
First tune October 2021 after fitting LMS header, cross over, TORs and Ramair.
Second tune February 2023 after drop in cams.

Third tune February 2024 fattened at low rpm to smooth out intermittent spitting back through the TB's and engine hesitation at 1800 RPM.
This third tune didn't solve the issue, the engine continues to have an intermittent hesitation at constant 1800 rpm (any gear) but runs smoothly on acceleration.
Easiest way to explain it is like an invisible foot dabbing the back brake every minute or so, no change to RPM but power loss is felt.

I've replaced the TPS, replaced the vacuum hoses, cleaned the air sensors and the crank sensor, replaced the MAP sensor, replaced the fuel filter, disconnected the stepper motor linkage, pulled most of the wiring loom connectors apart and treated them with dielectric grease, replaced the battery, replaced the coils with coil over plugs, run through 3 tanks of injector and fuel system cleaner.

Everything is within tolerance using TuneECU diagnostics, only thing I haven't done electrically is swap out the ECU.
The hesitation seams to be affected by the time to reach operating temp, the engines done 78,550km.
I've run out of ideas

 

[Mongler07]

Have you have the injectors properly cleaned? Removed and sent to a proper ultrasonic cleaning and flow benching? I mean it's really the only thing I can think of other than what I had... But my issue was a gear issue. 2nd gear popping out!

 

[Pete]

Have you have the injectors properly cleaned? Removed and sent to a proper ultrasonic cleaning and flow benching? I mean it's really the only thing I can think of other than what I had... But my issue was a gear issue. 2nd gear popping out!

I'll follow this up

 

[TURBO200R4]

Have you have the injectors properly cleaned? Removed and sent to a proper ultrasonic cleaning and flow benching? I mean it's really the only thing I can think of other than what I had... But my issue was a gear issue. 2nd gear popping out!

I have heard of a guy having problems because of the orings on injectors causing leaking vacuum .
Also leaking vacuum at the base of the throttle bodies.

 

[Fozzie]

I have heard of a guy having problems because of the orings on injectors causing leaking vacuum .
Also leaking vacuum at the base of the throttle bodies.

Its the crap rubber these companies use, if they get poorly stored, sunlight etc they fail

 

[Rocket Scientist]

Had a similar issue with my '05. Lift your gas tank and recrimp the low power wires on the coils (the coil for the front cylinder is a beotch to get at). Carefully squeeze them with needle nose pliers, so they fit tight on the terminals again. A little dielectric on the terminals doesn't hurt either. I didn't think it could possibly be that simple but it hasn't missed a beat in 8 or 9 years

 

[Terryfyd]

Thanks, I'll give it a try.

 

[Sir Digby Chicken Caesar]

Had a similar issue with my '05. Lift your gas tank and recrimp the low power wires on the coils (the coil for the front cylinder is a beotch to get at). Carefully squeeze them with needle nose pliers, so they fit tight on the terminals again. A little dielectric on the terminals doesn't hurt either. I didn't think it could possibly be that simple but it hasn't missed a beat in 8 or 9 years

Exactly what I did, yesterday. Worked a real treat!!

 

[Rocket Scientist]

Exactly what I did, yesterday. Worked a real treat!!

Gotta love a happy ending !

 

[Mongler07]

And this is why the coil over mod is perfect.
Those coils they have on them are trash