[thatowensbloke]

Hey all!

Got me a 450x a few months back, and its been running great. I should not have touched it before going away on a boys trip last weekend.....

I had the shock out last week for some pre-load adjustments and i think i may have damaged some wiring when i swung the subframe up.

Why do i think this, you ask?

Well, the bike will start and idle no issues. It will take small revs no problems either. Give it a boot full and it will hit what sounds like a rev limiter at about 3k rpm. it WILL NOT rev higher, no matter what you do.

Carb has been pulled, all jets cleaned. Fuel is clean, and inline filter added just in case. New plug (more on that soon) fitted and all other aspects seem fine. Bike just wont rev - either unloaded, or riding it.

The old plug was really white looking, so running pretty lean from what i know. replaced it while it was all pulled apart.
Fuel screw is set at 1.75 turns out.

Any ideas on what to look at? Anyone had anything like this before? i saw one post where the person ended up suggesting muffler packing of all things. i have not yet checked this, but it seems a little weird that it would just start happening one day (after pulling my shock out).

This is what it sounds like - https://youtu.be/AgJf99oxOmc

Cheers for being an awesome community!

Tim.

[JimDirt]

If it was running fine before you did the work , then I would check all the plug in connections by the airbox inside the door , etc. ....... Also ........... When you lifted the subframe , it is highly possible that you have pulled the engine ground wire out of the connector on the engine right behind the clutch actuator arm , and the sound that I am hearing in the video , is the ground intermittently connecting when the bike is bouncing around.......... First , look at the wire at the connector , and see if there is some exposed wire where it goes into the connector , if so , try tugging on the wire right at the connector , if it moves even slightly , then you need to unbolt and recrimp the connector (you can use channel locks), then check to see if the wire still moves , if it does not then reinstall it , and ride it again and see if that eliminates your issue ......

[thatowensbloke]

check all the plug in connections by the airbox inside the door , etc.

Thanks for replying JimDirt! Yeah, we had gone over it with WD40 in all terminals/plugs and couldn't fault it at the time.

I will check out your recommendations around the ground wire, hopefully its something simple like that!

One thing i forgot to mention in the first post was that when i flipped LOW/HIGH beam it made it worse. Up until this trip i didnt have a headlight bulb fitted at all - i was under the impression that the lighting circuit was completely isolated from the main engine circuit but there may be something here that i need to investigate also.
Cheers
Tim

[JimDirt]

Here is the wiring diagram , look it over and see if you notice anything different on yours with your lighting circuit

[thatowensbloke]

Here is the wiring diagram

Thanks mate, that's clearer than the one in my Service Manual for some reason! Where did you buy it from? I might need to buy a new copy!

[JimDirt]

I can't remember where I got it , I can barely remember what I did 12 minutes ago , let alone 12 years ago , I have had it for years , I think I got it right around when I joined this site , as that is when I got my 450X , I also have the actual written Service Manual as well as the Owners Manual

[thatowensbloke]

well, this happened last night....



found a few loose connections going into the CDI so i have soldered them back together again. i think i will have to pull the full loom out now, and check it all.

[JimDirt]

Well , that's not good ...... It looks like you have your work cut out for you ....

I am guessing that the prior owner either messed with stuff , or just did poor maintenance and now you are stuck fixing it all ......I feel for you ..... hopefully you get it sorted without having to replace everything

[thatowensbloke]

Well, I “fixed” it. It is back to normal, but I don’t think you will believe how.

Trial and error led me to remove the headlight bulb, and it came good! Bulb was added before last run but I didn’t even think about it.

Why could this be the issue? Well, my battery is dead. It’s still inline but it’s dead. Something about the headlight bulb loading up the charging system or something must’ve been it. I’ve ordered a new battery for it, so will be able to fully check once it arrives, but for now it seems to be resolved.

Cheers for the wiring loom diagram, that made me look over the whole thing and check it all properly.

Tim.