Pornstache - 02 1600

[davej]

Nothing in the starting system made it stall at 70mph. If you bypassed the battery cables and no change in cranking that eliminated those as the issue. Now lets get to a detail you mentioned. You said you had slow cranking with the sparkplugs pulled out. That isn't good. It should crank over super fast with them out and HC pistons wouldn't matter. This tells me it may be time to check to see if you have oil pressure. The 02 had a defective oil pump drive gear from the factory. They are prone to break and stop the oil pump from turning. I would pull 1 plug from each cylinder and loosen the oil line at the "Y" Banjo on the left side of the bike. Crank it over and you should have a high volume of oil coming out while cranking. If not your gear is broken and the engine may be partially/starting to seize up on the rod crank journals.
Here is a pic of the old style gear and the new updated gear. The 1 on the left is the old style gear, The ears break off and cause oil pressure issue. Notice the same area on the beefed up new gear

[Lug Nut]

What Dave j says makes real good sense....did you check to see if the recall was done on your bike? If so, maybe that is when the PO had hi comp pistons thrown in? Would make sense. You can call yamaha with your your vin and check. Also there should be a "punch" mark on the VIN area on the neck of the frame indicating the recall was done.

[Father Pobasturd]

From what I'm reading here, the bike has not ran at all since it shut off on the high way, right? Seems like your problem could be mechanical as opposed to electrical. When the motor stopped, did you still have power to the lights? Have you thought about trying to push start it? Might be tricky with the compression release, might have to disconnect the starter so you can use the starter button to hit the decompression device at the same time you dump the clutch, and definitely try it in 2nd or 3rd gear. If it supposedly has high compression pistons, a compression test might determine if that's true. Looking at the cylinders, is there any visual evidence of tampering? Was this cop you got it from the original owner? Did he do the engine work (pistons) himself, or pay someone to do it? Is there any paperwork to substantiate this? Could it be an owner prior to him who did the work, had it done, or just told him it was done?

You stated the bike "suddenly" shut off. Do you mean, like, seizure type sudden or just surprised you sudden? I'm not sure, come to think of it, if these bikes can even be push started. My wife had a Suzuki 650 Savage, a single cylinder but with a long stroke and a compression release. It couldn't be push started, it would just lock up the rear wheel, even in 4th gear. We tried it when the battery died on it once. Maybe someone else can weigh in here about push starting a Roadstar.

Of all the members here (over 1000) you could probably count on one hand the number of them who have different pistons or cams in their bikes. The likelihood of your 1600 being altered in this way is fractionally nil, albeit not impossible. Someone put pipes and a BAK on it, maybe they didn't stop there. Anyway your options are limited in this situation. Either keep messing with it 'til you figure out WTF is the deal, sell it for a loss, or part it out. We have a classified ads section on this site where I have bought and sold shit with good success. Whatever you choose, good luck with it. Looks like you have plenty of other bikes to ride anyway.

[MikeyC]

They can be coast started, when you dump the clutch hit the start button at the same time and it engages the decompression. Been there.

[MikeyC]

Just a note, if it may be oil pump related don't turn it over until you check the pump gear, it's easy, pull the side cover and clutch basket out and remove the gear and look ( if the previous test of loosening the "y" doesn't satisfy that is)

[davej]

If it is oil pump related and it is turning over slow due to being somewhat seized up, turning it over to check for oil pressure/volume won't hurt anymore than what is already hurt.

[GreasySam]

Wow, lots of good info!! I really appreciate all the help!

When it died, the lights stayed on. It was quick, but didn't feel like "locked up" quick. It was more like the fuel supply stopping suddenly. Since I was still rolling at 70, I checked my petcock real quick just in case. Then I tried roll starting it in each gear as I slowed down. Each time it was trying to lock up the rear wheel. I also had people push the bike down hill to try to roll start it - same thing. HOWEVER, I was not aware of the compression release at that time, so I never tried hitting the starter at the same time. Judging by how hard this thing is currently turning over, I'm not sure the compression release would make much difference. Worth a try though.

Thinking back on it now, while I was out riding, I noticed the exhaust looked a little dark coming out. Since the bike was new to me and I had not seen the carb or valve settings, I figured it could just be running rich. When I was at a red light, a guy pulled up next to me. He said that he is a Harley mechanic and noticed while riding behind me that the exhaust just didn't smell right. It was shortly after that moment that the bike shut down.

The oil gear scenario would make sense. When I get a chance, I will do the Y trick and check to see if I get oil. I will also check the neck for a punch mark.

[MikeyC]

Now that we're down here aways I forget what year the bike is. I think the oil pump gear was an issue up until mid 2003. If the motor is still turning I would still have hope. A seizing/bad bearing makes a definite sound, without that sound, just a smooth seize, I have got them going again and got many miles. That's in a car/truck but I think our road stars are a better critter.

[GreasySam]

The problematic one is an 02. The newer one is an 05. I never heard any kind of seizing noise when it happened and have never heard anything when trying to start it. Hopefully it was a smooth seize, if that's what happened. I would hate to give up on it because I know it has a lot of life left in it. I'll check the oil pump when I get some time.

[GreasySam]

. . . there should be a "punch" mark on the VIN area on the neck of the frame indicating the recall was done.

Any pics of what that looks like?

[roadiemort]

Any pics of what that looks like?

[GreasySam]

Thanks!

[GreasySam]

I will check again when I get home, but I definitely don't remember seeing that on the neck. If it has not yet been done, is the recall something that they do for free?

[roadiemort]

Yes, best to phone Yamaha for the truth as a picture is worth a thousand words if you click on mine lol.

[Doc_V]

I personally haven't see the actual words stamped, but my 99 had a simple asterisk above the VIN made with a punch:

[GreasySam]

Okay cool. I'll check for that as well.

[GreasySam]

I have been treating the 02 as a soft-seize. Once I buttoned the motor back up, I put some Marvel Mystery Oil on top of the pistons to let it soak. I left the spark plugs out and made a point of cranking the starter a few times a week to let it try to lube the cylinder again and work out the seizure. After several weeks of this I noticed that the motor was turning over significantly faster. So, yesterday I put the spark plugs back in and attempted to start it for the first time. IT ACTUALLY FIRED!!!

I only let it go a couple of revolutions since I haven't figured out for sure the cause. This makes my suspicion of the oil pump gear even stronger. Between my two jobs, family time and a never ending honey-do list, I only had a hot second to play with the bike, so I haven't yet checked to see if oil is pumping. Hopefully I'll get a chance some time this week. I needed that glimmer of hope though!

[GreasySam]

I like the passing light set up with the cross bar. The only one I could find that was specific to the RoadStar was the Cobra for $250. I found one meant for a RoadKing for $25 without lights and figured it was worth a shot. Obviously it wasn't going to line up, but I was able to cut and drill until I made it work. I had to cut the nuts off the inside of the windshield mount to slide it on the inside.

[GreasySam]

[GreasySam]

I bought a Stealth fairing with cutouts for a stereo from the USA Trailer store for like $270. I tried to dry fit it, but the stock risers were pushing it way too far forward and made it look ridiculous. Thankfully my other RoadStar had different risers on it, so I swapped them out.

[GreasySam]

I found a 2011 StreetGlide front wheel on CL and was able to snag it with both rotors and a good tire for $80. I bought some of Smokescreens adapters so I can run it. I ordered the recommended spacers from McMasters. The inner diameter was a little too small, so I drilled them a bit.

[GreasySam]

Found some vintage-style fog lights and some smoked turn signals. Mounted them up and put the fairing on.

[GreasySam]

I also mounted the front wheel and spaced the brakes rotors. Mine was 9/32.

[GreasySam]

I stripped the emblems off the tank and side covers. I also stole some parts off of my other RoadStar, like the ugly but super comfy seat with backrest and the highway bars. I finally understand why baggers are so popular, this thing is comfy!!

[GreasySam]

I still have to fit the hard bags and trunk before painting them.

Also, I'm only getting 25 mpg's. My ride to work is 40 miles round trip, mostly highway at 70-75, not throttle heavy. I'm 6'1, 250 lbs. It does have V&H pipes, but it appears to be the stock intake. I'm going to go pumpless, so I have the new needle and seat to put in. I will take the carb out and check the jetting. It may also be due for an air filter, I haven't checked it yet.

[GreasySam]

I had some aftermarket hard bags and a trunk that I found used on CL. They were red. I mounted them up and rode them for a bit before finally painting them. I'm taking my oldest to Nashville soon, so I had to finish putting it together.

[GreasySam]

By the way, I have officially thrown in the towel on the 1600. I checked the oil pressure and it was getting plenty of fresh oil. I put a little MMO on top of the piston to soak in as a precaution to make sure it had sufficient lube. I got it to fire, after just a couple of revolutions I heard a clank and saw sparks shoot out the tail pipe. Now it won't turn over at all. I'm over it. I'm totally happy with the 1700, so I'm taking it as a lesson learned and moving on.