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535 Resurrection Problems

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535 Resurrection Problems

PostAuthor: immortuiventris » Wed Dec 06, 2017 6:48 pm

Hello everyone.
This post is about my 90' 535 that i just finished rebuilding.
So. I finished almost everything except from the minor oil leaks (unto it) , fuel electrical petcock-diafragm-headache thing , and...electricity.
So facts first.
Measured Stator. Passed
Measured R/r . Kept changing results every half second, reminding me of a certain ex of mine. Dumped and Replaced with xlv650's rectifier.
Tried Riding. FAILED
Battery dead after approx 15 km. At first the bike was running perfectly. After about 5 kilometers ,each time i was stoping at a light or stop, the bike would sputter when trying to start rolling again. Evaded it dying on my by playing with the throttle a bit to keep it running. Stopped for fuel. BOOM. No power to turn starter.

Replaced battery with my 250s battery for a test ride. Same story.

Suggestions? I was so hyped when i started with this project. When i first got this bike it looked like it was momentarily dropped in the sea or something. Now it looks like it just came out of the factory and I get so disappointed with all this trouble with the electrical problems. Been working on this for 4 months already and im running out of funds and patience :\
Last edited by immortuiventris on Thu Dec 07, 2017 9:18 am, edited 1 time in total.
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Re: Electrical DeadEnd

PostAuthor: bstig60 » Wed Dec 06, 2017 9:08 pm

Route 66 battery probably too small. Sounds like a bad R/R. The proper unit for this bike is Yamaha 42X-81960-A1-00 RECTIFIER REGULATOR ASSEMBLY
You can find a replacement on Ebay. https://www.ebay.com/itm/Voltage-Regula ... 1947533730 ... The unit you have off the 650 is the wrong one, hopefully, you didn't burn out the stator.

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Re: Electrical DeadEnd

PostAuthor: Jake » Thu Dec 07, 2017 12:13 am

Never heard using the Honda R/R , did you check the charging voltage after installing the Honda R/R ?
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Re: Electrical DeadEnd

PostAuthor: immortuiventris » Thu Dec 07, 2017 3:28 am

Spoke to a couple of electricians here and did a thorough search online and found out i can indeed use another rectifier. for example the previous owner was using the 250s rr.
The present rr is giving me 13.7 or a bit lower (something like 13.4) on idle.
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Re: Electrical DeadEnd

PostAuthor: Jake » Thu Dec 07, 2017 7:09 am

Using another R/R is usually not a problem, as long as the amperage is sufficient to power the electrical system and keep, the battery charged, the 250 R/R may have been a little light for the 535.

The one commonly used here is a mosfet type Shindengen FH020AA, it's a definite upgrade.

I wonder if you have a bad ground connection. Double check your ground and maybe add a 2nd one from the battery to the frame.
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Re: Electrical DeadEnd

PostAuthor: jonno51 » Thu Dec 07, 2017 7:52 am

The one commonly used here is a mosfet type Shindengen FH020AA, it's a definite upgrade.[/quote]

Or you could order a brand new one, specific to the 535 from http://www.electrexworld.com

Their RR48 is a MOSFET type r/r

This might help too
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Re: Electrical DeadEnd

PostAuthor: immortuiventris » Thu Dec 07, 2017 9:16 am

Ok im gonna rename the thread to get help with other problems that have surfaced too.

Regarding the charging problem, im now draining the engine of the fluid to inspect the stator, (and fix some oil leakage i found).

On another matter, the engine is overheating too much. To the point that you can barely poke the side of the cylinders with your palm before you get burned...
I suspect the mixture is too lean? Any way to setup the carbs easily? I already synced them but im getting a hard time from finding the ideal pilot screw setting..
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Re: 535 Resurrection Problems

PostAuthor: immortuiventris » Thu Dec 07, 2017 9:22 am

Image


This is culprit..
XV 250 '88 Route 66 (The Good)

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Re: 535 Resurrection Problems

PostAuthor: jonno51 » Fri Dec 08, 2017 5:30 am

Looking good. Much better with some of the chrome painted over.
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Re: 535 Resurrection Problems

PostAuthor: eslmatt » Fri Dec 08, 2017 7:59 am

Reminds me of some girls I know... pretty but a complete mess where it counts :) I was smart enough to stay away.

You said it looked like it was dropped in the ocean... was it? have you cleaned the contacts and all that? Ever thought of doing your own wiring harness?
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Re: 535 Resurrection Problems

PostAuthor: immortuiventris » Fri Dec 08, 2017 3:21 pm

i am actually in the proccess of making one, but untill then (being a cook, i dont really have a lot of time for that ) im using the old one. Yep i checked all the contacts , cleaned them , replaced whatever didnt satisfy me to the slightest.
XV 250 '88 Route 66 (The Good)

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Re: 535 Resurrection Problems

PostAuthor: immortuiventris » Mon Dec 11, 2017 8:57 am

UPDATE


Ok. Seems like i fixed the electrical problems. Now ...
Over the last couple of weeks Iv'e put arround 18.5 Litres of Gas.
The bike did at most 50 kilometers. Now all of that gas is gone :S . There was a leak on the fuel petcock but that was like 1 drop per 3 minutes.I was this leak's fault or its just that the carbs are way off?

Now that we came to carbs. While the bike is running on idle, after 5-10 minutes, the engine becomes too hot, To the point that i can not touch it (and mind you, im a cook... i know hot).
So here are the facts of the engine as it is now. Whole engine was taken apart, washed with petrol, checked in accordance to the manual, put back together with new gaskets , and was painted black matt.
The pilot screws are turned right now at about half turn counterclockwise from their furthest point in (soft rest).

Also. I cant seem to find how to adjust the fuel floats in carbs. There is nothing that seems to adjust their upper or lower point. they just ...float? (Pennywise i guess?)
XV 250 '88 Route 66 (The Good)

XV 535 '91 UK (The Bad)

Me (The Ugly)

Hailing from Greece

immortuiventris
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Re: 535 Resurrection Problems

PostAuthor: immortuiventris » Sun Dec 24, 2017 12:46 pm

BUMP

The charging problems seems to persist :S im really at a dead end here...
XV 250 '88 Route 66 (The Good)

XV 535 '91 UK (The Bad)

Me (The Ugly)

Hailing from Greece

immortuiventris
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Re: 535 Resurrection Problems

PostAuthor: oberonspacefruit » Sat Dec 30, 2017 1:13 pm

Have the carbs been balanced? its a fairly easy operation, but requires a gauge.

If its using a load of fuel, logically, youve got to presume its leaking, or not being used efficiently,
if its not leaking much, you could do with dragging the carbs off. Are they Mikuni's?
in my exp, floats are adjusted by the tang that is atatched to the mechanism holds the floats in place.
Are you sure its the floats that are the problem? usually, a float just concerns itself with how much fuel is allowed into the bottom of the bowl to be used in the immediate future......
any day behind bars is better than a day at work......
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