Trans went

[verticalspark]

Yeah when you offer the front engine cover into place, you have to have the lifter shaft already turned anti clockwise so the spring is hooked and primed, and then turn the lifter shaft anti clockwise the final bit as it goes under the head of the lifter piece/pullrod, so the 'claw' on the lifter shaft hooks in around the back of the lifter piece / pull rod's head.
The spring keeps the claw from sitting against the back of the head when lever is out.

I am pretty sure I had it grabbed correctly when I put the cover back on. But, I will head out after this bit of school work and pop it back off and try again.

 

[wjb]

There is no way that the clutch lever should be that easy to pull in. The springs of the clutch are strong. They require much more effort than that to lift the clutch pressure plate up to release the clutch.
I too think that the fork of the lifter shaft has come disconnected from the lifter piece, that or the top of the lifter piece (the button part) has broken off the end. That happened to me.

 

[verticalspark]

Ok, I went back out and unbolted the cover, looked at everything again, and it was all good. I double-checked that I hooked the lifter this time, and it now works. Guess I'm a little out of practice. It still clunks at idle but once it speeds up a bit it almost stops completely. Its still there though so Im a bit nervous on how long it will last.

She starts and runs but the idle is a bit weird, and when you give it some throttle and let off, it takes a second for it to come back down. I ran through the TPS and ISCV setup again and the ISCV was back to 0.656. So I adjusted it back to 0.698 and reran the setup. And it was back to the mid-0.65s. So it looks like I will be ordering an ISCV, as the WD40 didnt make a difference if it was a bit stuck.

Secondly, I have just read the instructions on checking the secondary TPS and will try it later or tomorrow when I balance the throttle bodies so they are closer together.

Lastly, whatever tune is on the PC5 is now off because it gives a pop on decel. But I dont have the cord and I dont understand the tunes yet so I dont want to jump in and mess something up.

 

[Journeyman]

Ok, I went back out and unbolted the cover, looked at everything again, and it was all good. I double-checked that I hooked the lifter this time, and it now works. Guess I'm a little out of practice. It still clunks at idle but once it speeds up a bit it almost stops completely. Its still there though so Im a bit nervous on how long it will last.

She starts and runs but the idle is a bit weird, and when you give it some throttle and let off, it takes a second for it to come back down. I ran through the TPS and ISCV setup again and the ISCV was back to 0.656. So I adjusted it back to 0.698 and reran the setup. And it was back to the mid-0.65s. So it looks like I will be ordering an ISCV, as the WD40 didnt make a difference if it was a bit stuck.

Secondly, I have just read the instructions on checking the secondary TPS and will try it later or tomorrow when I balance the throttle bodies so they are closer together.

Lastly, whatever tune is on the PC5 is now off because it gives a pop on decel. But I dont have the cord and I dont understand the tunes yet so I dont want to jump in and mess something up.

The stepper motor is optional. I removed mine, as have many others. If you want a replacement I may have two, one new. Let me know and I'll go look.

runs but the idle is a bit weird, and when you give it some throttle and let off, it takes a second for it to come back down.

I still think you need a new primary TPS based on that, unless your cable or linkage somewhere is sticking. Most likely TPS. They go out regularly on these bikes.

I believe @R-III-R Turbo has a YouTube video on replacing the TPS- check that and his other stuff out.

 

[R-III-R Turbo]

Ok, I went back out and unbolted the cover, looked at everything again, and it was all good. I double-checked that I hooked the lifter this time, and it now works. Guess I'm a little out of practice. It still clunks at idle but once it speeds up a bit it almost stops completely. Its still there though so Im a bit nervous on how long it will last.

Put some resistance on the rear wheel and see if it stops.
Bet it is just the rear wheel moving faster (due to no resistance) than it is supposed to, so the dogs are hopping off either side of the gear window and not sat constantly against the driving face like it would be if the wheel was on the ground having to drive the bike forward.

 

[verticalspark]

The stepper motor is optional. I removed mine, as have many others. If you want a replacement I may have two, one new. Let me know and I'll go look.

I still think you need a new primary TPS based on that, unless your cable or linkage somewhere is sticking. Most likely TPS. They go out regularly on these bikes.

I believe @R-III-R Turbo has a YouTube video on replacing the TPS- check that and his other stuff out.

ok, well I might as well order a primary and secondary TPS. But while Im at it, I have the set that came off the other engine so I will swap them out and see if there is an improvement. But first I will check the secondary as that also may be the problem.

If you remove the stepper, are any benefits or other items needed to keep the bike running right?

Put some resistance on the rear wheel and see if it stops.
Bet it is just the rear wheel moving faster (due to no resistance) than it is supposed to, so the dogs are hopping off either side of the gear window and not sat constantly against the driving face like it would be if the wheel was on the ground having to drive the bike forward.

I will double check, but that sounds about right. Free spinning mass will outrun the gearing if the engine slows down

Hopefully I can get this thing back together, running right, done so I can quit driving myself crazy.

 

[Journeyman]

I have the set that came off the other engine so I will swap them out and see if there is an improvement.

That's a good plan.

But first I will check the secondary as that also may be the problem.

For some reason you never, or rarely, hear about the secondary going out.

@R-III-R Turbo is too modest to post his own videos, so here are two that you may want to check out...

If you remove the stepper, are any benefits or other items needed to keep the bike running right?

You'll need to manually set the idle screw- it's got the yellow paint on it indicating that they don't want you tampering with it . I'd recommend counting the turns so if you ever want to go back to the stepper you'll know where it was set. You could also take a closeup of it and count the threads. The stepper regulates the idle when the engine's cold. Without it you have to work the throttle until it warms up.

You can just remove the linkage to the stepper motor and leave it bolted on and plugged in.

Issues above idle are not the stepper, so if it's acting up at higher RPMs I'd leave that alone and focus on other things, including the primary TPS.

 

[verticalspark]

Well, here is an update. Its been either hotter than Satan's a$$hole here or storming quite badly. I finally replaced the TPS, and it does the same thing until it's warmed up. Rough run up but once it warms up it idles fine. Figured I would ride it for a day or two like that and see if its something else that works itself out.

I pulled the fuse panel looking and realized that whoever pulled them out played mix and match, putting them back in. I have to swing by and grab some 15s and 20s so I can match the layout.

But it also seems that my radiator fan has decided to join the stuff that no longer works. I tested the fan plug and got 12v to the plug during the test; there is continuity when I test the fan leads. So that's just something else I have to deal with now. I will get home and run straight 12v to it to see if it turns on. The power commander may have zeroed out and stopped everything working. I will check again ASAP.

I just wanted to let yall know that I appreciate the help more than yall can possibly imagine.

 

[Journeyman]

Without looking back, i believe that you removed the stepper. It will run rough until warmed up without the stepper. I think the TPS has you going again.... except now for the radiator :-(

 

[verticalspark]

Without looking back, i believe that you removed the stepper. It will run rough until warmed up without the stepper. I think the TPS has you going again.... except now for the radiator :-(

The stepper is loose and still not hitting 0.700. I left it alone but I may tighten it back up to see if there is a change even if its less than 0.700. And when the storms quit, i plan on putting 12v directly to the fan. If it works, then I will remove the PC and see if it fixes anything. If no changes, I will hard wire in the fan so I can ride.

I hit up the local part store to find a relay that I could use to replace the the one that is dead and the other two that will need to be replaced. I will break off the center plug and cover it and use it as a standard relay to see what happens.