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Post by ruckwilly on May 15, 2021 13:59:42 GMT -5
I have an stock 09 ruckus with 5300 miles, when i inherited it roughly ten years ago the only problem it had was an issue where it would randomly cut out after riding wot but it was intermittent enough that i just dealt with it as it always fired right back up. Lately tho it cuts out every time i drive wot for a minute or two, and it only refires after a few attempts and letting it sit for a minute. The same distance at halfish throttle and it does not cut out at all. Ive been through the carb and as usual things looked pretty clean to begin with. After making a smoke machine i found a leak at the airbox halves and the throttle seal behind the tps sensor . I used white lithium grease on the airbox and it seems to have helped. Just the tiniest squirt of carb cleaner on that seal makes it rev. I assume the carb cleaner is what took the seal out but i was wondering if anyone has replaced them before and if they are available. I have a rebuild kit on the way as i figured my bowl gasket and such needed replaced before i could diagnose further. I feel my charging system is weak as at idle it was only reading 11.7 volts at idle and only climbed to 12.3 when i gave it some revs. My fuel pump sounds normal but only supplies a trickle. I am currently charging the new battery again and was wondering if there was a common denominator to these problems im having and are there more definitive ways of testing these components. I am willing to try anything and i promise not to leave you guys in the lurch as soon as i give up or get it going like a lot of these folks seem to do. I have found a few similar posts but the creator just stops posting and there is no resolve. I just feel my diag skills have been slipping lately and id like someone to hold my hand and walk me through this lol. Help a brudda out!
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Post by ruckwilly on May 15, 2021 19:17:59 GMT -5
Decided to pull the tank to get at the fuel pump and thats when i discovered the vice grips still pinching the fuel line under the tank from when i cleaned the carb. 🙄 Anyway it sounds a lot healthier, havent been able to try wot yet since im watching the kiddo but i imagine it will be a bit better. I have no clue how it ran as well as it did with the supply cut off? The fuel pump isnt exactly shooting fuel but its more than a trickle now. As far as the stator , i was able to hit 13 volts but it sounded like i was revving it to the moon so i got some more testing to do.
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Post by Baizy on May 15, 2021 20:48:55 GMT -5
Decided to pull the tank to get at the fuel pump and thats when i discovered the vice grips still pinching the fuel line under the tank from when i cleaned the carb. 🙄 Anyway it sounds a lot healthier, havent been able to try wot yet since im watching the kiddo but i imagine it will be a bit better. I have no clue how it ran as well as it did with the supply cut off? The fuel pump isnt exactly shooting fuel but its more than a trickle now. As far as the stator , i was able to hit 13 volts but it sounded like i was revving it to the moon so i got some more testing to do. Thanks for an update so quick into the diagnosis period. You'll be pleased to hear that the fuel pump was never a super soaker and you're only going to get a pulse pump out of it. For the stator I wouldn't worry much about low revs only giving a low voltage output, that's normal in any variating generator setup. Revving it to the limiter when you're stock is fine btw, 8800 is safe for Honda and 10000 is "safe" for most ruck riders with a CDI and a good tune. Hope the vise grips removal got you sorted out proper! Happy Rucking |
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Post by ruckwilly on May 16, 2021 8:14:56 GMT -5
Thanks for the reply! Good info on the fuel pump and stator! Do you think the carb is savable with the leaking throttle shaft seals? Id pull it apart and inspect but im concerned it will be a special seal that i cant get. Been looking at carbs on ebay, the genuine one is $180 vs $50ish for a knockoff. Seems worth the extra money for such a vital component.
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Post by ruckwilly on May 16, 2021 9:37:26 GMT -5
After a lil research i found that i may be able to re lube the felt throttle shaft seals and that may get them to seal again.
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Post by ruckwilly on May 16, 2021 10:35:25 GMT -5
Took it for a ride, died at almost the exact spot it died with the fuel line punched off.? Kinda makes me suspect the pump now. I gotta get the obvious carb issues taken care of as it really effects the idle having the vacuum leak, just wondering around. Oh and another thing, when it cuts out after wot it restarts in a very similar manner to when its cold, takes a bit of cranking, wont respond to throttle at first but after ya baby it shes good to go. Another test i did was to go wot on the other stretch of road where it stalls right when i get off the gas to turn, this last time i decelerated gradually coming up to the turn and although it wanted to cut off i was able to save it after a few hiccups. Any way to know the amount of fuel the pump should put out in a certain amount of time?
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Post by Baizy on May 16, 2021 10:41:55 GMT -5
I'll check the factory service manual and see what I can dig up for you. 😉
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Post by Baizy on May 16, 2021 10:51:27 GMT -5
ruckwilly I got some info for you. The throttle shaft seals aren't a part you can buy so you're SOL there. I do have fuel pump info for you though. 100ml per minute is the MINIMUM flow rate so that maths out to 1.66ml per second. Best I can do on short notice.
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Post by ruckwilly on May 16, 2021 11:37:13 GMT -5
ruckwilly I got some info for you. The throttle shaft seals aren't a part you can buy so you're SOL there. I do have fuel pump info for you though. 100ml per minute is the MINIMUM flow rate so that maths out to 1.66ml per second. Best I can do on short notice. Exactly what i needed! thanks! |
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Post by Baizy on May 16, 2021 12:12:27 GMT -5
No problem ruckwilly! Hope you get it sorted! |
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Post by ruckwilly on May 20, 2021 16:29:32 GMT -5
Small update! Ive replaced all my fuel line and ordered a new fuel filter so i can replace it before i run the fuel volume test.
I pulled the carb off and put new jets and gaskets in it, upon further investigation of the throttle shaft seal after removing the C clip and the plastic washer it appears like there may not be a typical seal in these carbs. Unless its recessed into the casting because the shaft is a very close fit. I read on a few internet posts that the throttle shaft seals may leak at idle and is somewhat normal/tolerated. I also read you can hook a vacuum up to the carb and draw dielectric grease into the throttle shaft seal and re sealing it. I basically used a generous amount of dielectric grease on the washer and shaft, snapped the clip back on and topped it off with a little more so it was all coated and then replaced the tps sensor so any air leak should be slowed or stopped by the grease. Ultimately a carb replacement may be in order. I also slotted the new mixture screw.
Should be able to test it tomorrow at wot and see if it still cutting out, new filter should be here by then as well.
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Post by ruckwilly on May 20, 2021 18:45:19 GMT -5
Believe i have found my charging issue, i read on another forum that if you have higher than 35watt headlight bulbs then it will cause your charging voltage to be low, checked mine and they are 60/55 watt, unplugged them and its charging at 13.6-13.8 volts !
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Post by Baizy on May 20, 2021 21:40:11 GMT -5
Great stuff! I hadn't heard about the bulb wattage causing issue but it sure makes sense to me! Thanks for the update!
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Post by ruckwilly on May 21, 2021 12:00:24 GMT -5
So i replaced the fuel filter and took her for a spin, was feeling very confident till out of nowhere she died , and then a couple more times on the return trip. I know my air filter is pretty bad and im waiting on an OE one from ebay but its taking forever to get here. I feel pretty confident in the carb, the idle is perfect and it runs like a top all the rest of the time, after changing out the jets and a thorough cleaning to still have the same problem just seems a lil unrealistic. I usually run an ngk cr9eh-9 (country roads) but i have a cr8 on hand, thinking ill swap it out and see what it looks like after a run. Also noticed when it dies my fuel line stays completely full but i still plan to rig up a volume test on the pump. Only things left are coil, valve lash, cdi after that. Compression was 180 warm when i checked it but jumped up above 200 when i added a lil oil to the cylinder. Figure from sitting so much the oil rings may be sticking so maybe its worse than i thought. Ill try some more stuff this evening if i can get some time free.
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Post by ruckwilly on Jun 5, 2021 11:29:28 GMT -5
Finally got around to testing the fuel pump output, figured i could just hook the pump up to 12 volts and measure the output but that wasn’t the case as i guess the computer pulses the pump. I ended up bottle feeding it while i captured the fuel the pump put out. I only measured 21ml in 30 seconds. Should have been 50ml! So the pump is certainly my number one suspect but im going to jiggle the rocker arms while im down there and its all apart.
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Post by ruckwilly on Jun 5, 2021 13:57:05 GMT -5
Good news and bad news, valve lashes are spot on! But two of the lowest bolts on the valve cover gave me fits, managed to get one out and the hole chased but the corner one snapped. Extractor was unsuccessful so i have drilled it through. Something was up with the tip of both bolts causing it to bind up. I tried the tighten first then loosen but didnt help. In the meantime im going to order the pump.
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Post by Baizy on Jun 5, 2021 22:14:38 GMT -5
ruckwilly RIP your cylinder head. May the helicoil be strong and lock well. Damn the person the overtorqued those bolts!
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Post by ruckwilly on Jun 6, 2021 7:10:17 GMT -5
ruckwilly RIP your cylinder head. May the helicoil be strong and lock well. Damn the person the overtorqued those bolts! i was able to drill it out incrementally untill it was so thin that the threads were the only thing left, was able to peel them out of the top 3/4 of the hole and luckily the thread chaser pushed the remaining threads out of the back of the hole little by little. It was a pure stroke of luck but i aint complaining! Use a couple closely matched bolts from my Toyota hardware bin and disaster seems to be averted! |
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Post by Baizy on Jun 7, 2021 11:05:25 GMT -5
Great work! Here's hoping that the replacement fuel pump gets you all sorted out. You're so CLOSE!
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Post by ruckwilly on Jun 22, 2021 12:49:43 GMT -5
New fuel pump did the trick! Didn't miss a beat on my test drive! One observation is where the old pump just had enough flow to push around the air bubbles trapped in the line, the new one has enough flow to push the bubbles through the line. I have old vs new comparison videos but not sure i can post here yet. Gotta thank yall for the assistance and ill surely be hanging around.
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