998s Refurb

Whilst all the tools were out and before I went back into the house to research the ECU earth question I thought I’d lift the tank and take a look at the front injector connector again. Took it off and sure enough one of the connectors has been pushed back into the plug. You can see the one in the right is more recessed than the one on the left.



I’m convinced this is the cause of my intermittent misfire. Every time the connector is pushed onto the injector the spades in the injector push the connectors back down the plug rather than have something firm to push against and thus connect fully with the connectors. The poor connection with the injector is what’s causing the misfire IMO. It’s as though the little tabs that prevent the pushback and hold the connectors in place have either broken or are simply not doing their job. As I’m wiggling (wiggle is the word of the day today) the wires they both just came out of the plug .



Having had a close look at them and the inside of the plug I think the culprits are the tabs which the screwdriver is under and if I bend them out then push the connectors back into the plug they may hold firm. If anyone has any insight please do share it.



Alternatively I may need to replace the entire connector

 

What a cracking idea

 

Roger what? The pipes. You’re only small, I’ve some 45mm ones may be more your size

 

I’m gonna open up those tabs and then push the connectors back into the plug and see if they stay in place as they should. I’ve nowt to lose, worst case it’s the plastic tabs inside the AMP connector they push against that’s knackered so I’ll get a replacement.

Interestingly I read about so many other people’s bikes not running due a misfire and they’re pointed down the path of plugs/coils/HT leads/fuel pump/fuel filter/CPS/TPS/alarms/immobilisers/etc etc., and I wonder how common this particular issue may be .

 

Referring back to #241 and the one above I bent out the tabs as indicated and pushed the cables back into the plastic connector. Gave them a little tug and they seem to be holding firm .

Reconnected the plug to the injector, refitted the air filter and tank, turned her on and HOORAY she fires up and runs ; runs cleanly too, no misfires.



Only one thing to do now. Kit on and road test .



100km later, perfect, the connector repair has survived the bumpy West Cork roads no more misfire.

 

As I fitted wider exhausts the right hand rearset had to be spaced out, no way it was going back on with the 50-54mm link pipe in place. Temporarily I used 3 x 2.5mm washers I had laying around but I’ll have to pick up some proper collars, maybe 10mm as even with a 7.5mm space out the rearset, and especially the CF heel guard are still too close to the exhaust IMO. I’ve applied some heat tape to the back of the heel guard just in case.

 

When I removed the original ecu in order to replace it with one for 50-54mm I discovered it was earthed via one of the 2 bolts which secure it to the battery holder. As the battery holder is plastic and as the bolt is a 6mm bolt which passes through an 8mm tunnel in the ecu casing this doesn’t to me seem to be quite right. Especially as there’s a threaded 6mm hole directly beneath it which would be a much more secure earth. With a 6mm bolt in an 8mm hole it wiggles around, I just can’t see that’s the right place for it to be earthed.





It’s now earthed into the threaded hole beneath, making a secure and consistent earth. That’d be the one with the screwdriver stuck in it in this photo.

 

What did you do to your oil pressure switch there Ian?

 

Took her out again yesterday in the sun, now the dodgy connector to the injector’s been fixed and the exhausts are correctly fitted she starts first time and runs like a dream, no flat spots, no stuttering, perfect fueling (nice ecu @funkatronic , thank you).

However, the suspension needs some fettling (apart from the dirt which will get removed over the winter). The front’s ok but the back is way too harsh, bounces me all over the place and out the saddle at times. It’s not nice on the roads around here at anything over 75 unless the road surface is newly laid and race track smooth.

The spring is 1091-21 75 designed for 90-100kg riders with full gear. A bit light perhaps for me as I’m 97kg in the buff. I suspect however, it’s presently got too much compression applied, see photo.



I know they’re different shocks but the Showa on my 748 has only 5-6 threads showing now I’ve set it up correctly this has about 13 and the spring rating on my Showa is about the same as this one ie 75Nm.

I’ll have to book some time in SWMBO’s diary so she can help me set up the suspension properly for me.

Gratuitous photo shot