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501 Posts
Ok so I read about 50 posts on "won't start" and nothing solves my problem. So i bought this used 08 ER to replace my smashed 06 ER. I took it riding two days ago to see what this "stock" 08 would do. I made 3 hardcore rides and ran great. On the fourth ride 30 feet from the trailer I stalled and it wouldn't restart. Checked spark, fuel, and compression... all were fine. Bike turned over but wouldn't fire. Loaded it up and took it home to diagnose.
08 is completely stock except K&N air filter, tube filter in air box lid removed but lid still on and sparky and silencer removed.
First I checked timing and everything lined up. Cam up and facing back, crank dot lined up to case arrow, and timing gear mark lined up with carrier arrow.
Now I know there was a recall on the 08/09 decompressor so i started there first. It apperared and operated fine. With compression tester it tested out at 60 PSI, but just in case I installed an extra 06 cam carrier, cam, decompressor, and timing gear. Checked valve lash and adjusted shims to bring into spec. Set it to 55 psi and bike still wouldn't start.
So to eliminate possible carb issue, I removed my working carb from 06 ER and installed in 08 ER and bike still wouldn't start. (BTW the jetting is 128 main, 45 pilot, 2 3/8 turns out on air/fuel screw, 55 leak jet.)
Checked spark again to be sure and it appeared fine. Put in new spark plug just incase... still no start. Put in extra working coil and plug boot.... Still won't start.
Checked both closed throttle postion sensors. The one in thumb throttle and the one in the carb, both tested fine. Tested TPS and it tested out at 4.75 ohms (4-6 ohm range) Switched out complete thumb throttle, kill switch/light switch assemblies along with cables and plugs from the working 06 ER.... still wouldn't start.
Tried Rectifier from 06.... still no start. Tried ICM from 06..... still no start.
I have a the working wire harness and a known working stator I can try. other than that I'm not sure where to go.
Any advice???? Remember this thing was running then stalled and wouldn't restart, It currently turns over fine and builds compression, so starter clutch is OK.
I currently dropped it off at dealer to replace recalled decompressor... that is after i took out 06 cam, carrier, decompressor, and timing gear switching it back to original.
08 is completely stock except K&N air filter, tube filter in air box lid removed but lid still on and sparky and silencer removed.
First I checked timing and everything lined up. Cam up and facing back, crank dot lined up to case arrow, and timing gear mark lined up with carrier arrow.
Now I know there was a recall on the 08/09 decompressor so i started there first. It apperared and operated fine. With compression tester it tested out at 60 PSI, but just in case I installed an extra 06 cam carrier, cam, decompressor, and timing gear. Checked valve lash and adjusted shims to bring into spec. Set it to 55 psi and bike still wouldn't start.
So to eliminate possible carb issue, I removed my working carb from 06 ER and installed in 08 ER and bike still wouldn't start. (BTW the jetting is 128 main, 45 pilot, 2 3/8 turns out on air/fuel screw, 55 leak jet.)
Checked spark again to be sure and it appeared fine. Put in new spark plug just incase... still no start. Put in extra working coil and plug boot.... Still won't start.
Checked both closed throttle postion sensors. The one in thumb throttle and the one in the carb, both tested fine. Tested TPS and it tested out at 4.75 ohms (4-6 ohm range) Switched out complete thumb throttle, kill switch/light switch assemblies along with cables and plugs from the working 06 ER.... still wouldn't start.
Tried Rectifier from 06.... still no start. Tried ICM from 06..... still no start.
I have a the working wire harness and a known working stator I can try. other than that I'm not sure where to go.
Any advice???? Remember this thing was running then stalled and wouldn't restart, It currently turns over fine and builds compression, so starter clutch is OK.
I currently dropped it off at dealer to replace recalled decompressor... that is after i took out 06 cam, carrier, decompressor, and timing gear switching it back to original.
