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Discussion Starter #1
Hi everyone,
I just got an 03' Burgman 400 with 12.5kmi and it will crank but won't turn over. I have tried almost everything except compression test.
So far I have adjusted the valves ( were in spec at .021mm exhaust (bottom) and .013mm for the intake (top), changed oil filter, topped up coolant, checked fuses (all good)
I checked for a spark by removing the spark plug (looks new) and testing against the engine case , made sure the air filter is clean, even went as far as bypassing it for testing purposes.

I removed the fuel line going to the injector and put it in a cup and got fuel when the kick stand was put up (eg.primes fine). So maybe the injector is clogged since It was probably sitting for a few years before I got it, so I put fuel straight into the spark plug hole with no success. The FI/ check engine light don't appear after turning it on. The 10A ignition fuse is good. Battery is not an issue as I tried jumping it from my car.

What leads me to believe the injector could be clogged is that when I give it some gas while starting the engine doesn't sound any different than if I didn't. But I never had a FI bike before so maybe that's normal? Anyway to unclog/ free a stuck injector w/o disassembling? Tutorial?

I do hear a puff when I give it gas but it never turns over not even for a second. Anyone experienced that before? Flooded engine symptom?
anybody have any ideas how to do a compression check w/o buying the tool.
[youtube:22m567c1]N0hTsi4o_GQ[/youtube:22m567c1]
Engine running in background is my car I am using to jump the burgman

Also forgot to mention I checked using straw method in spark hole that the piston does move so engine is not frozen.
 

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Welcome to the forum. An introduction would be nice before asking for help. :thumbup: But to start off with some basic questions. Have got the side-stand up and the kill-switch set to run?
 

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A qick thing to try if you have not done so yet. Put the bike on the center stand then try cranking it with the throttle held wide open.
 

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Discussion Starter #4
Yes I put the side stand up. It wont crank with it down.
In the video I taped down the side stand switch so I could check the spark to the engine case. I tried cranking it with full throttle but it didn't work.
 

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Discussion Starter #5
I just tested the fuel injector by removing it, putting it in a small cup and starting the bike. It definitely squirts out fuel when the kickstand is put up. (Again b/c of fuel pump priming the system.)

However I tested to see if the engine was flooded by putting a non-white straw (so I could see the gas mark) into the spark plug hole. The very tip (a cm or so) had some gas on it. It's not flooded. Does anyone know how much gas it needs every stroke at idle?

I will put some sea foam below the fuel injector maybe clogged from there?
 

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Discussion Starter #6
Also I am curious why does the fuel injector spray fuel into the throttle body when the kick stand is put up? wouldn't that flood the engine?

Shouldn't it only spray fuel when the starter button is pushed? Or is my fuel injector stuck in the open position.
 

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Discussion Starter #7
I removed the fuel injector and dipped it a cup of sea foam with the hopes that it would free it up. Didn't work.

Now I am left thinking not enough compression? Why the puff at full throttle?? More questions than answers in the quest to the "truth". socrates method.
 

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If you have fuel and a spark you could try a little oil squirted down the plug hole
it may get compression up enough to start it, how long as the fuel been in the tank
modern fuels go off quite quickly and wile some old Brit bike will usually start on
it modern stuff often wont, does it smell like thinners, if so it needs changing.
 

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Discussion Starter #9
Ralph M said:
If you have fuel and a spark you could try a little oil squirted down the plug hole
it may get compression up enough to start it, how long as the fuel been in the tank
modern fuels go off quite quickly and wile some old Brit bike will usually start on
it modern stuff often wont, does it smell like thinners, if so it needs changing.
I siphoned out a gallon of the old fuel and put in new gas before I began this process. 10/1 new to old is probably what's in the tank right now.
Will try the oil in spark plug and report back.
 

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Any possibility the cam chain jumped time? I don't know if the 400 is an interference engine, but if not, the cam may be out of time and allow the motor to spin, but not start... Maybe the previous owner was doing something needing head removal, and didn't time the cam correctly.
 

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Discussion Starter #11
I just checked the compression and am not getting a reading at all. To make sure my gauge wasn't faulty I checked my lawn mower and got 50psi.

Unfortunately the previous owner didn't leave the old spark plug in it so I can't deduce what happened to it.
1more piece of info when I got it there was very little /no coolant in it.

Also to confirm the "TDC line" that the service manual refers is the upright "T" on the rotor?
 
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