Running Poorly

Honda XL 600 discussion forum:


Running Poorly

Running Poorly 
Rob in Sydney said 2009-04-27 14:24 
 
I need help. Any ideas?
Starts OK.
Idles OK.
Above about 2500 RPM, will not rev freely, engine seems to intermittently “blow back” out primary carb when it misses.

This is what I have tried:

Electrical

Rewound stator, tested exciter coil to CDI with oscilloscope, lighting coil OK and charging coil OK.
Tested pulse coil to CDI with oscilloscope - OK
Checked timing and observed advance with timing light
Swapped CDI box
Swapped spark coil
New spark plug

Fuel

Cleaned carburettors
Cleaned tank
Removed air filter
Cleaned fuel filter
Tried different jets
Originally
Primary 108
Secondary 105

Tried 112 and 125 and the original jets in all possible combinations without success and in most cases seemed to make it worse.

Tested without air ducting – when engine misses there is some fuel mist exit from primary carb
Tested without PCV

Mechanical

Checked valve clearance
Tested without muffler
Re Checked valve clearance
Checked starter decompressor
Checked manual decompressor

Any assistance much appreciated, thanks.
 
 
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