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Pornstache - 02 1600

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  • Pornstache - 02 1600

    I have been wanting a RoadStar for over 6 years now. They have always been out of my price range. I recently came across a motorcycle cop that bought himself a new Ultra and was getting rid of his old Roadie on the cheap. It has a little over 50,000 miles on it and does not appear to have been very well maintained, but I couldn't pass it up. Got it for $2200.

    My long term plan is to build a 60's style chopper out of it. In the short term, though, I need a bagger. I have three kids and told each of them when they were little that on their 16th summer, I would let them pick a place to go and I would take them on a roadtrip with me on a motorcycle - just me and them. Neither of my other two bikes are great for roadtripping two-up. Well, time flies and I just realized that my oldest daughter turns 16 this year and my other daughter turns 16 the following year. So, I need this to be a bagger for the next two summers. My youngest is 7, so I have time to build another bagger before then (ha ha).

    Here is the bike right after I got it home.
    Just a dude, playing a dude, disguised as another dude.

  • #2
    I found a set of hard bags and a trunk on CL for $300. They are also a little beat up and I will have to do some work to make them fit, but I've got my start!

    I've only had the bike a couple of weeks. I checked the oil when I brought it home, it could use a change, but the level looked good so I rode it to work a couple of times (40 miles round trip). Every time I start the bike, it is very slow to turn over. The PO said it was because he put a cheap battery on it. I hooked it up to a fresh battery to check it and it made no difference. It still turned over very slow and seemed to barely start.

    I went on a ride the other day and got about an hour from home when the bike suddenly shut off while doing about 70 on the interstate. I got to an exit and pushed it up the off ramp to a truck stop. I tried restarting it there, but I could only get about 1 revolution out of it each time I tried. I thought maybe the battery was dead, so I jumped it off of a car (with the engine off). It made no difference. Still would only turn about 1 revolution. I got it home and changed the oil and filter just in case. I pulled the spark plugs and turned the motor over. It was still turning over slower than it should, but was turning over freely. I put he plugs back in and it's back to 1 revolution. I found in the forum about cleaning out the starter and checking the compression release. The PO told me that it has the high-compression pistons in it. Hopefully that's it. I will let you guys know how it goes.
    Just a dude, playing a dude, disguised as another dude.

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    • #3
      A few of us have found the starter brushes broken on the 90 deg bend of the tabs. Could be your slow to crank but wouldn’t shut down a running bike. I also had to bend my compression release spoon slightly.

      Comment


      • #4
        Originally posted by daveto View Post
        A few of us have found the starter brushes broken on the 90 deg bend of the tabs. Could be your slow to crank but wouldn’t shut down a running bike. I also had to bend my compression release spoon slightly.
        Good to know, thanks!
        Just a dude, playing a dude, disguised as another dude.

        Comment


        • #5
          I took the cover off of the decompression solenoid and watched it as I tried to start the bike. It is pushing the decompression rod like it should. I'm assuming pulling the head covers and watching the exhaust valve is the only way to really know if it is working?

          I also removed the starter and took it all apart. It already looked pretty clean. The only dirty spot I could see was a little ring on the back cover. I went ahead and cleaned it all up anyway with electrical cleaner just to be sure.

          I put it all back together - no change at all. Still only turning one revolution. AND I burned up another starter relay.

          Pics below are prior to cleaning the starter.
          Just a dude, playing a dude, disguised as another dude.

          Comment


          • #6
            I suspect you didn’t take it far enough apart? Or didn’t take pic... Click image for larger version

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            • #7
              The shiny gold spot is the broken part of brush tab I was referring to. It should be connected to other side. Also in case you haven’t been told you need the Yamaha starter relay. All others have been found to fail early or not work at all. The other option is an upgrade to a car relay like you normally see on older cars on the firewall.

              Comment


              • #8
                Originally posted by daveto View Post
                The shiny gold spot is the broken part of brush tab I was referring to. It should be connected to other side. Also in case you haven’t been told you need the Yamaha starter relay. All others have been found to fail early or not work at all. The other option is an upgrade to a car relay like you normally see on older cars on the firewall.
                Ah, good call! I did not take it far enough apart then. I will check that out when I get home. Thanks!
                Just a dude, playing a dude, disguised as another dude.

                Comment


                • #9
                  I just want to add you look amazing in that dress !

                  Comment


                  • #10
                    Originally posted by Rob in FL View Post
                    I just want to add you look amazing in that dress !
                    Thanks! Hahaha, that's actually Sean Connery. Even with my wedding dress on my mustache isn't that awesome, so I used his photo instead.
                    Just a dude, playing a dude, disguised as another dude.

                    Comment


                    • #11
                      I pulled the starter back apart and checked to make sure the bracket was in one piece, it was. I discovered that I must have dropped one of the thin washers inside the starter when I was putting it back together the first time because I saw little burn marks all over (glad you had me check). I also lightly sanded some of the connections to clean them up more.

                      Put it all back together and tried again. Still no difference. I printed off some of the starter testing pages from the manual. I will try that. If the starter checks out, I may have to pick up some of those famous starter wire kits I keep hearing so much about on here. And, of course, an OEM starter relay.
                      Attached Files
                      Last edited by GreasySam; 08-26-2018, 03:30 AM. Reason: Adding picture
                      Just a dude, playing a dude, disguised as another dude.

                      Comment


                      • SuperG
                        SuperG commented
                        Editing a comment
                        Jeebus, must be some hella huge compression in those cans!

                    • #12
                      [Real quick - I want to apologize for this build thread starting out as more of a tech thread]



                      Okay, so I pulled the armature motor out and performed all three of the tests to determine whether or not the starter motor is good. It passed all three tests.

                      This got me wondering if there is something else between the battery and the starter that is causing all the trouble, so I did a quick and dirty test to bypass everything in between. I hooked up a jumper cable to the starter and connected the other side directly to the battery (in short bursts to mimic using the starter button). To my surprise, it made no difference. The motor would still only turn about 1 revolution. I thought maybe it somehow had a bad ground connection, so I did a voltage-drop test to check. No loss in voltage at the starter.

                      This made me think that perhaps the decompression spoons weren't making full contact. So I pulled off the cover and pushed the decompression rods in simultaneously by hand while cranking the motor. IT STILL MADE NO DIFFERENCE.

                      I am at a loss. At this point, I can only think of two potential causes.
                      1) The starter motor is bad (even though it passed all three tests)
                      -OR-
                      2) The exhaust valves aren't actually opening like they should to decompress.

                      My plan right now is to pull the head covers when I get some time and check the valves. Unless of course someone else has a better idea. (Testing a new starter would be easier, unfortunately I would have to buy one just to test it).
                      Just a dude, playing a dude, disguised as another dude.

                      Comment


                      • #13
                        Or borrow one... Where are you? I'm in MA, between Boston and Prov. RI.

                        Comment


                        • #14
                          Are your battery terminals clean and dry? I’m wondering if it could be so dumb as a bad connection at your battery and you also clamped your booster cable over the factory terminal with the same poor connection? Just a thought before you dig deeper.

                          Comment


                          • #15
                            Originally posted by Questcap View Post
                            Or borrow one... Where are you? I'm in MA, between Boston and Prov. RI.
                            That's true. I'm in Columbus, OH. There are quite a few gents on here from Ohio. I'll check out the valves first and see if that makes any difference. Thanks.
                            Just a dude, playing a dude, disguised as another dude.

                            Comment


                            • #16
                              Originally posted by daveto View Post
                              Are your battery terminals clean and dry? I’m wondering if it could be so dumb as a bad connection at your battery and you also clamped your booster cable over the factory terminal with the same poor connection? Just a thought before you dig deeper.
                              Yeah, a bad connection was one of my first thoughts. I cleaned them up and made sure to put the cable directly on the battery post to eliminate any possibilities of a bad connection.
                              Just a dude, playing a dude, disguised as another dude.

                              Comment


                              • #17
                                Any updates?
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                                • #18
                                  Originally posted by Ron Caudill View Post
                                  Any updates?
                                  I haven't given up on this one yet, but I did buy another RoadStar over the weekend. The newer one is a 2005 Midnight Silverado in much better shape.

                                  I took a day off work last week and did nothing but work on the 02. Cleaned the carbs, installed a new intake manifold, adjusted the valves, cleaned up electrical connections, etc. I was pretty excited to try firing it up again. Put it all back together - no change. I took the starter and battery out of the 05 and put it in the 02. No change. I took the battery out of the bike and ran jumpers directly to the starter (to eliminate the possibility of the starter wire causing the issue) - no change. I took the starter from the 02 and put it in the 05 and it worked just fine. So this tells me it's not the starter and it's not the battery.

                                  There has to be something internal causing this.
                                  Just a dude, playing a dude, disguised as another dude.

                                  Comment


                                  • #19
                                    Is it possible for a moderator to update the title of the thread? Since the 1600 pooped out on me, I'm following the same plan with the 05 1700. It would make sense to update the title.

                                    Instead of: Pornstache - 02 1600
                                    Change to: Pornstache - 05 1700

                                    If it can be done, it would be much appreciated!
                                    Just a dude, playing a dude, disguised as another dude.

                                    Comment


                                    • #20
                                      These bikes are cheap to buy and own. Sounds like you got some basket case that wasn't taken care of. Sell it. Don't waste time trying to figure out something that a PO did/didn't do that is causing headache. Keep the nice one sell the shit one and move on. I like fiddling with my bikes but won't spend a minute trying to figure out some bullshit mod some other idiot did. Like hi com pistons the po said he did. Whom didn't he work? Was it done properly. Buy a stock/stockist Roadstar for $2k-3k with low miles and ride and modify as YOU like. No return in spending time and $ on an old metric bike that will never be worth more than $3k when you sell.

                                      You have learned a great lesson on Roadstars....if you constantly have odd issues and can't seem to fix it....it's because some hillbilly fucked it all up before you got it. You just about NEVER hear anyone talk about all their issues when they have and stock bike. I've worked on some pieced together basket case bikes and it's horrible. These and re the best value longest lasting plain ol simple air cooled v twin machines you can buy. Not supposed to be hard to work on or a headache....the selling point s are price and reliability.

                                      hate to see you mess with a lost cause instead of riding.

                                      Comment

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