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ViragoTechForum.com » XV535 » New here, 535 runs for a while, then dies (SOLVED)

#1: New here, 535 runs for a while, then dies (SOLVED) Author: valenzano,

Posted: Sun Jun 06, 2010 4:16 pm

Hi everyone! If I'm not doing this right, I'm sure you'll let me know. I'm new here.
I have a 1987 XV 535
I've been reading the forums for a while, and I haven't found something that matches my exact situation, so before I start taking the carbs apart, which I really am not comforable doing, I thought I'd ask.

It ran well when I bought it two months ago, except (I just realized this) the choke was always in the 'on' position. (Dies when I move it.)

It's not running so well now.
Short background story: It first cut out while I was out riding, and lost electrical power. It had a new battery, so I figured it wasn't charging. Found a fault-finding flow chart, followed it, and determined that the regulator/rectifier (RR) was bad. Bikebandit.com wanted something like $212 for it, so I read up on here and got one from a junkyard 1984 Honda Shadow for $4. Fixed! But...

A couple rides short rides later (about 35 miles) It cut out again, mid-ride, and died. This time it still had electrical power, and cranked just fine, but wouldn't start until I let it sit for maybe 20 minutes. Then it would start and run for a short distance, (like, 400 feet) then die again. The throttle response is choppy. As I twist it it first sort of bogs, then races after it reaches a certain point up to full open, but then it bogs completely and dies. If I try to ride with throttle about half open it surges forward intermittently. Also, makes subtle 'puff'/hiss out of intake that I didn't notice before. (I have the dummy tank off.)

Looked in the float bowls, everything looks nice and clean. It's got good electrical, unless there's a short or something, but the battery's charging. It seems like fuel starvation or carburetor issue, maybe? I checked fuel filter, it's very good, no blockage. I ran some 93 octane from sunoco with about a third bottle of gumout carb cleaner, which should be enough to treat about 7 gallons, cuz the bottle says treats 21 gallons.
I've run about six gallons through since I got it, so gas should be good.
Plugs look okay, but I got new ones today so I can read them better. (NGK's, like the old ones.)
Seems to be firing on both cylinders, at least most of the time, because they both get warm while it's idling.
I took the gas cap off, no change in idle. Doesn't seem to be a vacuum problem.
Fuel pump seems to be working, unless it fails once it warms up or something. (Although, it still clicks to pressurize the system when I try to start it immediately after the bike dies.)
Both plugs have spark.

I can't seem to figure it out. Anyone have a suggestion?

Thanks!

Last edited by valenzano on Sat Jul 17, 2010 9:00 am; edited 1 time in total

#2: Author: club_c,

Posted: Sun Jun 06, 2010 4:46 pm

valenzano wrote (View Post): ›
...the choke was always in the 'on' position. (Dies when I move it.)...

There's your first clue. Either fuel flow is reduced to the carbs, or more likely vac leak. Opening the gas cap doesn't show anything about vac leaks.

valenzano wrote (View Post): ›
...Also, makes subtle 'puff'/hiss out of intake that I didn't notice before...

There's your second clue. Vac leak, maybe at the carb holders. Check all your vac lines too, sounds like one is knocked off.

Let us know what you find.

#3: Author: valenzano,

Posted: Sun Jun 06, 2010 5:18 pm

Thanks, I'll check on the vacuum lines. Can you tell me which ones are most likely at fault/most critical? I don't really know which ones are vacuum lines without some investigation.

Also, the new spark plugs help a little. When I took old ones out I found that the front was a little gummy.

#4: Author: club_c,

Posted: Sun Jun 06, 2010 5:24 pm

Need someone more familiar with the vac lines on the 535. If you take some carb cleaner and spray it around the carb boots you'll know if there are leaks there - the idle will pick up.

#5: Author: club_c,

Posted: Sun Jun 06, 2010 5:24 pm

and all the lines will be 'critical'. One bad vac line can ruin your whole day.

#6: Author: valenzano,

Posted: Sun Jun 06, 2010 7:12 pm

Okay, new spark plugs, and I removed the fuel line to the carburetors (which someone had put behind the rear cylinder instead of to the side of it) and re-routed it to the outside of the frame so it's not so close to the rear cylinder. I also tightened the hose clamp on it, tighter than it was, although it seemed tight before. I sprayed some WD-40 on the carb holders, although I couldn't see any sort of visible damage, and I don't know if WD-40 would help seal a crack if there is one. (got a suggestion for sealing cracks in rubber?)

I took it around the block and it SEEMS much better, but I don't trust her yet. I'll have to take it out on a longer ride with a friend.

#7: Re: New here, 535 runs for a while, then dies while riding Author: kathybrj,

Posted: Sat Jun 19, 2010 8:01 am

I'm having the same issue with my '94 xv535s. It runs great for a short time and then starts to sputter after it gets hot. If we let it sit for about 20 minutes it will start again, but then does the same thing.

My husband is leaning in the direction of ignition coils; however he is going to replace the spark plug wires first since they seem to be taped up and not looking too healthy. Hopefully the wires will solve the problem because that's the more economical route to go at this point. confused

#8: Author: valenzano,

Posted: Sat Jun 19, 2010 8:39 am

I just dropped my insurance since Allstate was jerking me around, trying to charge more than they quoted. They also have terrible customer service, and they didn't know what proof of insurance or an insurance card was. Also, they frequently hang up on me and forget to fax me things.

As soon as I get new insurance I'll be taking it out for a longer ride to see how things go. I, too, was worried about ignition coils. We'll see.

#9: Re: New here, 535 runs for a while, then dies while riding Author: kathybrj,

Posted: Sat Jun 19, 2010 9:19 am

Ok, so much for plug wires being the economical route. Called the local dealer and he says they come with the coil for $210 a piece. Ouch. eek

We're now looking into other options...

#10: Re: New here, 535 runs for a while, then dies while riding Author: FrankR,

Posted: Sat Jun 19, 2010 9:34 am

Re: Insurance

When it comes to life insurance, I think it comes down to One word only: Geico.

They sure do know how to do their jobs. Nothing but an amazing experience.

#11: Author: Jake,

Posted: Sat Jun 19, 2010 9:37 am

valenzano wrote (View Post): › I sprayed some WD-40 on the carb holders, although I couldn't see any sort of visible damage, and I don't know if WD-40 would help seal a crack if there is one. (got a suggestion for sealing cracks in rubber?)

You spray the WD-40 while the engine is running. If a vacuum leak is present at the carb holders there will be a noticeable change in engine speed.

#12: Author: coalstoves,

Posted: Sat Jun 19, 2010 2:12 pm

You guys better learn to shop better I can get an accel super coil and 7mm wires for under $80 . I also don't think there’s anything wrong with you wires . I restored an 87 535 bought non running from a college kid in Jersey you will need to clean the carbs if it spent a duration in storage with fuel the design of the BSD carb condemns the jets in storage I have articles in the KB about parts and settings and a video on utube search read and ask me .

RR trouble - getting a junk yard part was a mistake they are prone to failure so much so elctromotorsport has a service bulletin about them all viragos 2nd gen at least use the same item including the 535 got new for $65-100

Ricks motorsport electrics
Electrmotorsports
Accel

All these folks offer replacements .

Carb parts use Yamaha parts the carbs are proprietary to Yamaha they bought the design from Mikuni, not much exists outside what Yamaha has and they still sell everything you need.

#13: Re: New here, 535 runs for a while, then dies while riding Author: kathybrj,

Posted: Sun Jun 20, 2010 8:53 am

Yup- called one dealer- $210 for coils. Called another dealer who took a few minutes and came up with the Rick's Motor Electrics coils for way under $50 each. Too bad Rick doesn't sell them off his website.

My running problem is almost taken care of now that the float bowl levels have been adjusted. It runs and rides much better. My husband spent many hours cleaning the carbs to get it running as well as it is now. New NGK spark plugs as well.

#14: Author: valenzano,

Posted: Sun Jun 20, 2010 11:04 am

Kathybrj - New plugs and carb cleaning sure helps. Not sure if my problem is solved, but it definitely runs better after plugs and cleaning.

coalstoves - Thanks for the info.
I don't see why I shouldn't use a junkyard RR. It cost me $4, so if it ran for two weeks I got my money's worth, and, besides, it can't possibly be a crappier design than Yamaha's RR with no cooling fins, right in front of the muffler. I actually mounted it on the left side, frame, near where the shaft drive meets trans. It's a solid RR, and it works. Not only that, but it looks just like the later model 535's where Yamaha decided it was a better idea to make one with fins and put it right where I did.

#15: Author: coalstoves,

Posted: Sun Jun 20, 2010 10:53 pm

R/R's are too prone to failure I have seen a brand new aftermarket one fail in just a year .

Now $4 is a good deal ,,, 2 weeks from now and 100mi from home with a dead battery I'd like to ask you the value of the $4 R/R,, its a crap shoot who knows might last another owner or two or not .

#16: Author: valenzano,

Posted: Fri Jul 09, 2010 8:13 pm

Well, if anyone's still reading this, it's definitely not fixed.
It runs fine for maybe 10-15 miles, or less at 55mph, then it chugs out and wont start until it cools off. Sometimes the fuel pump wont stop clicking. I believe it's trying to build up pressure and it cant. I cant find a vac leak anywhere, though. Could something be clogged and cause this?

???

Does anyone know what causes puffing/hissing from intake? Is it a cylinder not firing?

I have some titanium and neoprene tubes. Thinking of just replacing all the fuel lines, once I look it up and see if neoprene is solvent-safe.

If it is a vacuum leak, why does it seem to only happen after it gets hot?

Open to suggestions and tips.

Thanks all

#17: Author: coalstoves,

Posted: Fri Jul 09, 2010 10:52 pm

Pump constantly clicking means the fuel is not making it to the pump OR the floats stuck open or set way High in one or both carbs and flooding thus not stopping the fuel .

What is the condition of the plugs when it dies wet or dry .

Hissing manifold yup sounds like a vacuum leak to me maybe

Fuel pumps are for the most part trouble free so don't spend time figuring out whats wrong with it, it's prolly fine .

#18: Author: valenzano,

Posted: Sat Jul 10, 2010 10:40 am

From another forum, sounds like my problem...

"...Do you feel a little "puff" out of the air cleaner when it happens? I was able to lessen the pop a bit by backing out my idle mixture screw 1/2 turn, but its still there every once in a while..."
"Popping back thru the carb is a sign of a lean mixture. Running lean enough to backfire thru the carb isn't a good idea, too much chance of engine damage from overheating."

...where is the fuel mixture screw?

#19: Author: coalstoves,

Posted: Sat Jul 10, 2010 11:10 am

You are required by request of the moderators to include bike info in your signature and activate it before soliciting help .
(See Members Announcment)

SEARCH Mixture Screw and my username
(saves me typing over again)

#20: Author: valenzano,

Posted: Sat Jul 17, 2010 9:04 am

Well, I figured it out, finally. The fuel uptake tube from the gas tank (before the fuel filter) was clogged with brown gooey sediment. I put a little WD-40 in there and ran a steel cable through. Cleared it right out. Thanks everyone. I'll know better next time what to look for.

#21: Re: New here, 535 runs for a while, then dies (SOLVED) Author: negaurx7girl,

Posted: Fri Aug 13, 2010 2:39 am

I was just going to suggest that, as that was a problem I had a couple weeks ago. It ran for a few minutes, then died. Well, I replaced the fuel line coming up from the pump and found that gunk in there. now that you found that brown gunk, make sure you replace your fuel filter - new fuel pump for this bike is $415 and new carbs are almost a thou apiece

#22: Author: valenzano,

Posted: Fri Aug 13, 2010 12:17 pm

Yeah, I KNOW! I ran this steel cable through the metal uptake tube from the fuel tank, and it got the stuff out, but a few days later there was bits of chunky stuff in the fuel filter. Replaced it. Thanks.

Sure took me long enough to figure it out. Wish you'd been here earlier.

ViragoTechForum.com » XV535 » New here, 535 runs for a while, then dies (SOLVED)

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