My thought was to take a bunch of mini-rides to let the new engine break-in and go thru a few heating/cooling cycles. We first rode to the local Veteran's Memorial park about 5 miles away to pay tribute and reflect on what the sacrificed. Thanks Vets! No problems on that leg of the ride.
From there we took the scenic rout down by Lake Monroe, putting along mostly between 35 and 40mph. After about 15km I stopped at a little sady sopt on the side of the road to let the engine cool and take some pictures.
After a 10minute rest, we were off again and avout 10km later while riding down a deserted country road a 45mph the engine just died! :o No sputtering, no funky noises, no burning smells. Sounded like you hit the kill switch. Just a loss of ignition. After about 10 minutes of alternating head/butt scratching and looking at things (got gas, got juice to all the lights, starter turns, motor moves freely, got blinky light on the ignition, pulled and checked all the fuses).
I decide to pull the front rotor/coil cover and see if there is anything out of place there. My best guess is something in the wiring or ignition was grounded or disconnected. I tried calling Bill Glaser and Holopaw Gene and left messages for both of them.
I pulled the ignition module off the perch (where the horn is on my 650) and let it hang, pulled the front cover and wiggled all the wires. I wanted to see if the rotor was turning, so I just turned the key on and thimbed the starter for a sec, and the bike fires to life! :D Not sure what the problem was there. Just to be sure I shut the engine off and tried her again and it fired up immediately. :D Freakin' mystery why it stalled.
So I put the rotor/coil cover back on (it's metal - why not plastic?) and put the igniton module back on and go to fire it up and the starter wont work! > I got hed lights and running lights and turn signals, but no alternator, high beam, or nuetral dash lights!
Glaser called me on the celly and told me to check the wiring to the battery and the wires that plug into the alternator. All those seem OK. My next thought was maybe that when I was swinging the handlebars back and forth to get to the frint rotor cover bolts maybe something came loose in the wiring harness. So i pulled the headlight to take a look in the bucket. There's a white plastic connector there that's loose but it doesn't plug into and a red wire with a female smade connector loose that doesn't go anywhere, but there's no place for those to plug into. :cry:
I dragged out the manual outta the trunk and it's pretty useless! The wiring diaram is all in black and white and squished down to fit on a single sheet of paper and ya can barely read the lettering! > Funny thing is, I printed out the wiring diagram callison posed a link to in color on 11"x17" paer at work earlier in the week, but I left it on my desk! What a dummy!
I decide to pul the front rotor cover again, just to see if I pinched anything or monkeyed something up putting it back. About that time, Gene calls. I explain the lack of electricity to him and he asks me to check the fuses. I checked them earlier before I pulled the front cover I told him. He said to check them again. There's a 5A circuit, that I guess picks the relay for the starter and lights most of the dash lights. Sure enough that fuse was blown. Gene said I might have pinched the small wire that comes out of the top of the rotor/coil cover. I pulled one of the 5A fuses outta the accessory box in the sidecar, popped it in there and viola she fires to life.
Since the missus is now hot and been listening to me mutter and curse for the better part of an hour. I decide to leave the front cover off and just remount the ignition module. Threw the front cover in the hack, she hopped in tthe tub, I hopped on the bike and off we rode again! :D
Stopped at a convienience stor a few miles up the road, got some cold drinks and then my wife says "maybe we should go home", which in SWMBO-speak means "were going home". Fired it up no problem and we cruised about 20 km home at 45-50 mph without incident. It's a fun sweet running machine. I am very happy with it.
Other than that one side of the road session, no other problems. The rig feels like its really having to pull to get to 50mph. That mid range throttle area seems a little flat. But I am successfully resisting the urge to tinker with anything until I get a few hundred km on it. I'm waiting for it to cool down before I put the fron cover back on it. Maybe I ouhgha get one of them plastic ones?
I still have no idea what caused the initial stall. Not sure if the blown fuse problem had anything to do with it.
I had hoped that the maiden voyage, especially with the missus would have gone better. Now she's all freaky that were gonna get stuck. I had to explain to her that it would not be a proper Ural trip without one of these stops! :surprise: Ural - the ultamite adventure rig!
Pic of the missus in the hack (before the side of the road session):