Stumped

[dfunkesq]

I have been trying to repair my voyager and I can't figure out the problem so I thought I would ask the experts. The bike will start and idle but when I give it throttle it will die. I rebuilt the carbs and it still does the same thing, when it is running and I pull the plug wires on the number 4 plug there is no change in the idle speed or a change in the way it is running all the others there is a change. I pulled the plug and checked for spark and there was spark. Does anyone have any ideas?

Thanks in advance
Dave

[dfunkesq]

I have checked the igniter with an ohm meter and the readings on some of the terminals do not match what is in the book, some are infinite that should not be could this be my problem?

[SgtSlag]

I guess I would follow the OEM Service Manual's recommendations. Otherwise, give Carl Leo a call. His contact information is listed at the top of nearly every page on this site. Best of luck. Cheers!

[kjsett]

I have been trying to repair my voyager and I can't figure out the problem so I thought I would ask the experts. The bike will start and idle but when I give it throttle it will die. I rebuilt the carbs and it still does the same thing, when it is running and I pull the plug wires on the number 4 plug there is no change in the idle speed or a change in the way it is running all the others there is a change. I pulled the plug and checked for spark and there was spark. Does anyone have any ideas?

Thanks in advance
Dave

This is maybe too simple, but sometimes when an electronic device doesn't work, I just check the plug at the wall.
Anyway, It doesn't sound exactly the same, but the kickstand down switch will kill the engine. Maybe related??????????? Maybe not, since it kills the bike when you start out.
Just gave me a moment of "OH NO" when I was 400 miles from home and was scratching my head (first ride after picking the bike up 480miles away from home).
It still catches me occasionally.
Have a great day and good luck.
ken

[ekap1200]

I have been trying to repair my voyager and I can't figure out the problem so I thought I would ask the experts. The bike will start and idle but when I give it throttle it will die. I rebuilt the carbs and it still does the same thing, when it is running and I pull the plug wires on the number 4 plug there is no change in the idle speed or a change in the way it is running all the others there is a change. I pulled the plug and checked for spark and there was spark. Does anyone have any ideas?

Thanks in advance
Dave

check the basics . ie . fuel, spark, and compression. If #4 has compression,, carb has fuel and you have a good spark, check carbs sync.

[Mr Jensee]

I know you said you cleaned the carbs but I am betting the carb on the cylinder you say you have no change when you pull the plug I bet still has clogged jets. That will prevent the engine from coming up from idle when you pull the throttle. Idle jets just affect idle so the bike would idle fine. check that carb one more time and do a thorough cleaning. Then have them sync'd.

[chevyman1]

Also check the fuel filter and if it is real dirty you might have to check the carbs again

[suzib6sw]

Dave
Measuring the Ignitor with anything other than the Kawasaki tester will not return the expected results..

What it sounds like is you have an air leak assuming the carbs went back correctly.. Did you have this issue before taking them apart?.
the most likely area is the inlet boots from the lower air box to the carbs.. Believe me, they are total pigs to get right 1st time.
Does it do it with the boxes off too?
When you rebuilt the carbs, did you clean the jets with a carb cleaning tool? Did you get the float height set at 17mm with the floats just resting at an angle on the valve? Are the stoppers on the two inner carbs (vaccuum take offs for a balancer etc)..
Cheers..

Pete

[dfunkesq]

Wow lots to answer and thanks to all for the responses.

Ok yes the bike did exactly the same thing before I took the carbs apart, the carbs was pretty gunked up and I might have missed cleaning out some jets, so I will check that out.

After just receiving another igniter yesterday and installing it and the bike is still doing the same thing compression is what I am going to check next, unfortunately i don't have a compression tester and will be getting one tomorrow, Kawasaki doesn't have a special one that testes the correct compression do they?

I always thought that ohms was ohms I really have a hard time believing that my $200 fluke won't read the ohms correctly on the igniter, but it is what the book says, by the way I have the igniter #1179 with 150k miles and no problems to this point, just got one #1248.

The kickstand thing, doubt it because I have it up and the bike is on the center stand, but the way it
acts is just like that, I will check that out. This problem is very strange because one day it's running
fine the next this problem, this is why I rebuilt the carbs. The floats are set at 17mm and done the way it was said! I'm not sure I understand about the stoppers on the 2 inner carbs though. It does the same thing with the air box off.

Is it possible the timing chain slipped?

I am about ready to look for another bike, i really love this bike it has taken me a lot off places and a lot of miles, I have definitely got my monies worth out of it. I hate to see it go.

[Me Again]

It's easy enough to check the #4 cylinder.
Pull the plug.
If the plugs dry ,go back to square 1.If it's wet ,your probably getting fuel so go to square 2.
It's always a good idea to use the updated igniter .Use the old style and some cold morning your going to go out and the starter will hesitate for just a moment ,and there goes the chain.

[Bruce in OK]

I don't believe it is possible for the timing chain to slip. I tend to think your fuel system is still not 100%.

[chevyman1]

Might want to check your fuel pump.
I read somewhere that with the tank full the engine will run without the pump but won't run at higher RPM .
Your symptoms sounds like its running out to fuel for some reason.
Try revving it up until it shuts off as soon as it does turn the key off (I think the pump will stop when the engine shuts off anyway) Then open the drains on the carbs and see if any fuel comes out and how much.
That should tell you if the fuel is getting to the carbs

[dfunkesq]

As for the fuel pump I got the napa one recommended in tech tips but the same problem.

[chevyman1]

Just another idea, You might want to check the big plug from the fuse block and also check the wire from the ignition .
I had a broken wire in the wires coming from the ignition and with the engine idling I wiggled the wire and engine would stop.
And the big plug gets corrosion on the pins.
If there is a wire tie on the front left frame rail just behind the steering remove it, That causes the wires to brake.
These are two known Voyager problems.
Just remember it worked before it can work again.
With all the help you will get from the people on this form we will get it figured out.

[Mr Jensee]

spray some ether / starter flluid around the carb boots while the engine is running and check for air leaks. It still sounds to me like you are not getting enough vacuum pullling fuel into the engine. If your float bowls are full then it is isn't your fuel pump or the filter. Make sure the diaphragms on the CV carbs don't have pin holes in them.

[Chris near Kansas City]

I'll go one further than Mr. Jensee. Just slip the boot off #4 and spray WD40 in there with the bike running and see if #4 comes back in.

You should still be able to rev the engine up even with a cylinder or 2 dropped, so it sounds like something else is suspect, that is, if like you said, the bike was fine one day and not the next.

This problem is very strange because one day it's running
fine the next this problem, this is why I rebuilt the carbs.

Are you saying it was fine one day and the next it wasn't? Or that it is intermittent, meaning one day is fine, the next it's not, the next day it might be fine, the next day who knows???

[gearheadfla]

There is a part in the carb kits Carl never uses because it causes problems, he reuses the part that was in the carb, it's covered somewhere here. Maybe thats whats going on. Just a thought.

[chevyman1]

That part is the little wire clip on the float needles.
the aftermarket ones can cause the needles to hang open

[Mr Jensee]

Yeah but when those float needles hang up the fuel will dump out the drain tubes. If you aren't experiencing that it is likely not your problem.

[chevyman1]

Does it shut off clean or does it spit and spuder or does it just not spin up