2003 636 Idle Problem

[!!A2K!!]

A dyno will show if its running lean/rich. Im sure the dyno and tune will fix the problem. U cant add better airflow to an engine and expect it to run good on oem settings.

[ROWDY]

Originally Posted by Twite

3 different sets of TB sensors. Different reed valves (cleaned them out for good measure).
Seats and valves were checked and in great condition.

Trying to get it on a dyno tomorrow or Friday to get some real numbers!

For reference, mine makes right at 106 whp with slipon pipe and pc3

[Twite]

Originally Posted by old man roger

Twite this is a total guess but if you have a spare pickup coil it would only take a few minutes to swap it out, if for no other reason than to eliminate it as a problem.

Normally they either work or they don't but as stuntriders we always seem to find the random strange failures..lol

Some manufacturers call it a pulse coil, some a pickup coil.

It's just a magnetic sensor that reads the position of the crank so the ignition coils know when to fire, it's under that small cover on the right side of the engine in front of the clutch cover.

Swapped it. No difference.

I think I may swap engines and use these current sensors, ecu, and harness. This should let me know if it is in fact the head work.

[ToKwik]

Originally Posted by Twite

Swapped it. No difference.

I think I may swap engines and use these current sensors, ecu, and harness. This should let me know if it is in fact the head work.

I guess that's one way to do it. I know its easy to pop and swap a 636 motor, but 5 min on the dyno I think will tell you more.


Just out of curiosity, have you checked the wires to the sub-throttle assembly?

One other place I've found issues is the wiring for the cam sensor getting cooked. I now wrap those in heat tape during reassembly.

Hope you get it figured out.

[Twite]

Originally Posted by ROWDY

I just dont see this being the problem solver. If it were a lean condition it would run like poop all of the time, ESPECIALLY when you start pumping a lot of air in the motor (high rpm).

Either way, I have a PC3 w custom map you can try and a spare good engine if you end up needing one

I don't either at this point...but there's nothing else. I have changed EVERYTHING.

[!!A2K!!]

Originally Posted by Twite

I don't either at this point...but there's nothing else. I have changed EVERYTHING.

Did you pc3 and dyno yet???? Ive said this 3 times lololol

[!!A2K!!]

Twite, did you get the head decked as well or just port and polish?

[ToKwik]

A PCIII won't fix any run-ability problems.


The only other weird thing I have come across that may be related was a bad fuel pump. Bike would run fine, but wouldn't idle worth a damn.

Pump ended up only putting out about 20psi when it needed to be double that.

[Twite]

I've tried fuel pump.

PCIII didn't make a difference. I tried adding 10% and subtracting 10% fuel in the low rpm range (1000-3500). Didn't get a reaction, positive or negative.

I believe I have no officially tried everything. Going to swap in another engine, but use the current harness, ecu, and sensors to see what happens.
Sooo excited...

[!!A2K!!]

Originally Posted by Twite

I've tried fuel pump.

PCIII didn't make a difference. I tried adding 10% and subtracting 10% fuel in the low rpm range (1000-3500). Didn't get a reaction, positive or negative.

I believe I have no officially tried everything. Going to swap in another engine, but use the current harness, ecu, and sensors to see what happens.
Sooo excited...

Was the head decked???