ok here is the situation: i recently aquired an exracing mc21 R that had had a SP engine put into it. I bought the bike knowing that it had issues with pgm3's (ie it had blown about 3 of them) Anyway after consulting with a mate and coming to the conclusion that its obviouly an electricial problem causing the pgm to continually blow we proceeded to transplant the SP engine in that bike into my bike. which too is a mc21 R.

Ok the engine was sucessfully swapped (thanks Bryan and Karl!!) and all electrics from my bike(which were in perfect working order) are being used. first start up resulted in one very smokey and melted PGM3. (thats 4 its been through) realising that the only thing that remained on the SP engine from the race bike was the stater coil and wire. Ahh this must be the poblem we all thought it has to be there isnt anything else remaining from the other bike. Anyway changed it over and was running fine (considering the pgm was blown and the valves wernt set yet)

a new PGM arrives (onc again thanks to the above mentioned). first start all goes well!! so i then adjusted the valves as directed in the tuning section, kicked 'er over and once again smoke pouring out the pgm. (THATS 5 and they aint cheap!!)

anyway to make a long story longer im buggered whats wrong with it, as is everyone else. the top end has only done about 50km since rebuild, i run jha pipes, pods on the carbs which was dyno tuned if it makes any difference.

Does anyone have any ideas, suggestions, anything....... what could be causing the pgm to continually blow....

AS i said a PRIZE (havnt decided what yet!!!) will be given to the person who can solve the problem... (oh yeah and if anyone has a pgm they wanna sell let me know....)

just to add... there seems to be a lot more really white smoke from he top cylinder than the lower...

Have you swapped the power valve servo motor? How are the power valve cables? Do they slide freely? I have read that sometimes the power valve servo and/or power valve cables will get frozen/jammed up, causing the PGM to blow.

Larry
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1993 Honda NSR250
1989 Honda NSR50 (100cc bore up)
1992 Honda NSR50 (80cc Engine)
1993 Honda NSR50 (Project bike)

How about the oil injector solenoid? Did you use the one off your engine, or the other engine? Or are you even using it?
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Paul Herr
'88 FZR4/GSXR/YZF Frankenbike
MY BIKE PICS

Have you opened the burnt PGM up to see were it is coming from ? http://www.nsr250.net/forums/viewtopic.php?t=596
This one had a seized Rc servo motor, you can see to the right one of the beer can like transistor is exploded, also were the podding has been removed the smoke will come from that area. Don't know if that helps ?
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wrench. wrote:How about the oil injector solenoid?

Good call Paul, I didn't think of that component myself!

What about the G.P.S.? Have you used the original one, or the one attached to the SP motor? Maybe a short in there somewhere?

Are you using the original "R" or the "SP" carbs? I saw an MC18 in Thailand pop a PGM due to a faulty T.P.S.; again something "wired" to the PGM.

Andy.
NSR-WORLD.COM

yep servo motor and cables were swapped to mine. The oil solenoid???? I think from memory the 'sp' one is still on it. yeah buggered if i would have thought of that as well... ill check it out and get back to ya on that...
Andy the gps was swapped and im using the carbs off my R. thing is it was blowing pgm's with the other carbs as well. how do ya tell if they're sp or R carbs???

thanks for that link Jeff im gonna rip it apart and have a geeza later this evening.

andy** wrote:how do ya tell if they're sp or R carbs???

The carbs on the "R" and "SP/SE" are the same. There are different types depending on year though. It was only a thought because of the T.P.S.

Andy.
NSR-WORLD.COM

Dear Andy**,

First of all happy new year to everyone, I have been a little busy the last 2 weeks.Andy** the pgm is blown when you start the engine or when you turn the main switch on?I suggest that you should first disconnect all the peripherials that aren't needed for the engine to run like, TPS, lights, stop switches, oil pump (poor some oil in the gasoline), GPS, side stand switch, Oil switch, power jet solenoids.Start the engine and see what it does.If it blows again let us know.Have you changed the wiring harness?????

Padelis

does anyone have a component list for the pgm. If you do I can probably repair and re-programme it.
Psycho

psyche, yeah the complete wiring harness has been swapped over. i still havnt had a chance to swap the oil solenoid ill get back to ya with the outcome. Oh and yeah it starts smoking about 20 seconds after i kick it over its fine just with the ignition on.

I'd definitely start by unplugging the servo motor for the powervalves. It draws a lot of current, and sadly is fed directly by the PGM, not from an external relay switched source.

Have you had the lid off any of the PGMs?
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

So does it perform the RC Valve tests without the motor running OK? (With a healthy PGM!)

IGN off >> kill switch off >> unplug T.P.S. >> IGN on >> kill switch on: RC Valve opens.

IGN off >> kill switch off >> connect T.P.S. >> IGN on >> kill switch on: RC Valve closes.

This would indicate the servo and RC Valve operation is OK - in test mode, at least!

Andy.
NSR-WORLD.COM

Good point.

What happens if the igntion is switched on, but the engine isn't started?

A short circuit would show up under these conditions. If nothing bad happens it would indicate that the bike is fine without the motor running, therefore you've got something drawing too much current once the enigne is going, rather than a short somewhere.
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball

yeah servo cycles fine with the new pgm. it only starts to smoke once the engine is started. therefore must be something drawing to much power like you say dave. thing is, everything that draws power was swapped to the gear that was on my bike which was going sweet as. i have t6o get the top off the old pgm to have a squizz its at my other place though with my bike sitting in the shed. ill have to go get it tomorrow.

Ok, what about the reg/rect and the alternator? Maybe some serious overchanging going on - check the battery voltage at about 5000 rpm...
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MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball