New handlebars, no longer starts. What am I missing

sphynx88

Been Around the Block
Decided to put on a new set of handlebars last month. 30 days later, my bike is back together but no longer starting. Would love for it to be something basic, but I really dont know what else to check. I'd love some suggestions. The bike is cranking strong, just not turning over. Here is what I have gone through:

Before this, my bike has started reliably all 10-15 times I had startered it since buying. The PO had issues with the carbs flooding, attributed it to gunk, cleaned it up re synced and since then hadn't notice any issues. The gas is getting low (maybe 1/3 of a tank) and has been in the tank since April. The gas is getting old, definitely but again it had NO problems until I took it apart.

My first major snag came from the removal of the control boxes when a soldered wire tore off the starter button. I re soldered it and routed those two wires down alongside the handlebars. I also had issues getting the throttle grip to snap back properly. This has since been fixed.

Second came the issue of my clutch cable not being able to adjust it. I believe I got it sorted (bike now moves when clutch handle is pulled in, feels like there is just enough tension) but I havent been able to test it fully since the bike wont start.

Third, when I got the bike back together and it didn't start I wanted to check for spark. When pulling one spark plug I noticed it was hard getting back in. A little too much force stripped the head and I had to retap and put an insert into the spark plug hole. Was getting blue spark on both of the plugs now.

I did pull the gas tank to deal with some wiring issues. Since the bike has been off, I went through and cleaned up all of the connections, regreased and sorted some grounding issues.

Today, I pulled the petcock, removed any crud in their, sprayed some starting fluid down the carb lines and made sure the carb bowls were full. Check and check. The gas I'm sure was there from when the bike ran back in September but now they are empty. I am unsure if this is a major issues or not.

What am I missing? The bike cranks well and I have drained the battery several times trying to get it to start.

I am new to bikes, so maybe my starting process needs work but the petcock is on, the choke is opened slightly and I hold the clutch cable in and the front brake.

Fuel: Possibly old? Possibly low? Sprayed starting fluid in carb lines and emptied the bowls to make sure there was gas in. Bowls are now empty. How can I fill them again?
Compression: Shouldn't have changed.
Spark: Blue-white in new gapped plugs.
Electrical: Bike cranks and getting spark? Is there anything else to check that would prevent it from starting? Possibly not a great enough ground. Battery was at 12.1 after trying to get it to turn over for awhile...
Timing: Didn't touch
 
From skimming thru your question (sorry), I want to say it's old gas. You said it's been sitting at least 30 days, then from April on top of that.

Gas is cheap (ish). Unless it's got some type of stabilizer in it, I would pitch it after 30 days alone.
 
I'll start there.

Non ethanol fuel is harder to come by around me would 10% be alright or should I add an additive to it?
What is the best way to drain fuel, just petcock on and attach fuel lines to a gas can?
Last question, since the fuel bowls are empty, what is the best way to get them full again, just cranking?
 
when you turn the petcock to "On" fuel should flow into the bowls. (Unless the bike has a vacuum operated petcock). If it doesn't, pull the bowls and make sure the float isn't stuck
 
warthogcrewchief said:
The handlebars require a ground wire so that the switches can be grounded. Did you reconnect the ground wire?

Yes but the bike is still cranking when I press the button and I tested voltage to the wires and they turned seemed okay. The kill switch also turns off spark.
 
lingo said:
when you turn the petcock to "On" fuel should flow into the bowls. (Unless the bike has a vacuum operated petcock). If it doesn't, pull the bowls and make sure the float isn't stuck

I'll go verify this. When I had the bottom of the petcock off and switched it on. I got fuel everywhere but didn't check the 2 nozzels going to the carbs.
 
Alright checked the petcock. Flipped to on, it had a couple of drops coming out but once I switched it to reserve it started flowing what I assume is normal. I'll empty the tank and pull the petcock and make sure it is cleaned out again. If the fuel bowl is full wouldnt the bike at least start or does it actually need the pressure of incoming fuel to get anywhere? I supposed once it decreases to a certain level it wont push fuel above the float...
 
Drain carb bowls. fill tank w fresh gas, open screws on carb bowls, open petcock, fuel should flow through carb float needles and drain from carbs. close carb bowl drain screws. Charge battery, Install new plugs...check for spark at plugs...then spray some starting fluid in carbs. If you got spark and fuel and air, she will try to run.
 
You guys have restored my confidence! Looking forward to wrenching tonight.

Final 2 questions:

1.) I am use to working on auto carbs. There you just open the butterfly's and spray starting fluid down the primaries. How is it done on a motorcycle/where would the location be?
2.) Again with the 10% ethanol around me. It's at least a 45 minute drive to the nearest ethanol free station. Do some guys run 10% with an additive?
 
1. go easy with the starting fluid. a little goes a long ways on a bike. Yes, roll the throttle open and shoot just a little in the carb.

2. I try to run ethanol free gas but it isn't always available. If I know the bike isn't going to run for any period of time I put an ethanol treatment in the tank and empty the bowls on the carbs.
 
Pulled the petcock up. Cleaned it out the best I could. Drained the gas tank, new gas/full tank and it started right up. Rode it about 5 miles yesterday :D
 
sphynx88 said:
Pulled the petcock up. Cleaned it out the best I could. Drained the gas tank, new gas/full tank and it started right up. Rode it about 5 miles yesterday :D

Another note. There should be little holes on the bottom side of the gas cap (under the gasket) ... Make sure those aren't clogged, it allows the gas to vent. Happened to me and couldn't track it down for the longest time.
 
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