Dave,

The reason it had a top end strip down was because a base gasket had been fitted on one cylinder and the old one not removed. Two gaskets were clearly visible, one of which had been doubled over and creased and it therefore had to be removed. On removing that top end we showed you the pictures of the incredibly poor finishing to the cylinders you had bought, along with the scuffing to the exhaust bridge which meant that the bike was very near to seizing. You stated that you did not want/could not afford to have the cylinders replated at this stage and to rebuild it as is.

On rebuilding the top end we reset the powervalves correctly.

We replaced the front coil because the top was broken and the wires inside were very corroded. This did improve the performance from how you delivered the bike to us, but did not cure it.

Then the battery was checked as this is always the first port of call on NSR's that run poorly. It was fine.

Following that we striped and inspected the carbs. Most of the breather tubes were either missing, or routed incorrectly, so these were fixed. The air screws had also been set totally wrongly so these was set correctly. Again, this improved things from how you delivered the bike to us, but did not cure it.

We explained to you that some of the problem was down to your airbox. This had random cutouts all over its top, as well as having all the internal crosswebbing removed by someone with a poor handling of a Stanley knife. At some point in its previous life it had been fitted incorrectly and the rubbers on it folded over. This now meant that it was hard to form a good seal with the carb mouths. For some reason it had also had the rubber bellmouths that protrude into the airbox also very crudely and badly removed. As a result of this the airflow that the carbs needed was being badly disturbed and the bike actually ran better with no airbox at all, than with the one you have. We therefore recommended that you replace it.

You have forgotten to mention that I told you the PGM has problems. We swapped it with one from a bike that has no problems and a number of other electrical problems that your bike has that you haven't mentioned were cured, although it made little difference to the running. Therefore, that also needs to be looked at as it is a known problem and may be causing others of an electrical and poor running nature.

As fas the wiring loom is concerned I told you that there are almost certainly problems with it. There were connectors in the middle of wires that should have been straight runs for no reasons whatsover, there were splices that appeared to have no function and in many cases wires with connectors and splices in them were exposed to the elements without any insulating tape round them. I explained that while on a stand the bike appeared to run fine most of the time, but that it intermittantly had problems. I pointed out the TPS in particular to you as being a potential problem as it was missing its inner shroud that keeps it firmly located, although given the state of the loom as a whole it would probably be better to replace it with a complete new one. I also explained to you that I could replace it if you wanted, but as cost was an issue you preferred to look at this area yourself.

Jo
Apex Leisure