Athena what?

Sooo....any gurus out there?

Installed an Athena 290 kit this weekend.
Some snafus but caught everything.

Took it out for a test ride, seemed to surge and basically run like shite.
Stopped ad did some fiddlin' with the FMF fuel controller after it stalled then came back on.
NO biggie, that's happened before.

Then took it up on the freeway. Bad choice.
Went about a mile and it just died, dead...tow truck time.

I've checked the fuel pump, pumping fuel.
Checked for spark. Plug looked good, I have spark.
Took the FMF controller out of the loop.
Still it won't start or run....

Cam timing looks spot on...

I'm scratchin' my head here.

When you say you encountered some SNAFU's, what do you mean? Do you have a compression or leakdown tester? That doesn't sound good. If you have air, and you have fuel, and you have spark, you're likely low on compression, or have a massive leak. Check your head bolt torque numbers, make sure everything is snugged up.

Initially it sounded like a timing issue, but if it ran, and now doesn't, points to large issues. Did it make any strange sounds, or just cut out? What's it sound like when it cranks?

Cranks over fine, as usual, no metallic sounds.
Just shut off, dead and coasted to a stop.
Never made any 'bad' sounds.

I suspect it's got something to do with the cam chain adjuster.
May have not engaged. My feeling is the chain jumped a few teeth....

...oh snafu's

One of the cylinder spacers fell into the crankcase when I pulled the cylinder.
Almost forgot to insatll the second wristpin circlip....a real bitch BTW...

Rapid Dog wrote:

Cranks over fine, as usual, no metallic sounds.
Just shut off, dead and coasted to a stop.
Never made any 'bad' sounds.

I suspect it's got something to do with the cam chain adjuster.
May have not engaged. My feeling is the chain jumped a few teeth....

Rapid Dog wrote:

...oh snafu's

One of the cylinder spacers fell into the crankcase when I pulled the cylinder.
Almost forgot to insatll the second wristpin circlip....a real bitch BTW...

That's good. Certainly a possibility. Does it sound like it wants to fire at all? Usually if the timing's off like that, it'll pop and crackle and backfire; do everything but start.

I'd double check the tensioner, valve clearances, and if it still won't start, borrow a compression or leak down tester and see what you're getting for numbers.

Those circlips are pesky. You did install them in the 6 or 12 o'clock position, yeah? Seen those suckers pop out under load before if installed differently

...dropped it down and pulled the valve cover.
Pretty sure it's what I thought it was.

The cam chain tensioner was deployed, and the exhaust cam was off one or two teeth.
I think what I did was forget (didn't read the 'structions close enough) to engage the tensioner after setting the sprockets and closing it up.
So, it would run, but not so great.
I'll redo all tonight.

It still doesn't make sense to me why it just died though....we shall see what happens when it's back together.

...oh... and yes, every few revolutions albeit sporadically, when the starter is turning it over it made a lil fart now and then.

Rapid Dog wrote:

Took it out for a test ride, seemed to surge and basically run like shite.

That's generally a sign that it's running too lean. Assuming of course, your cams are correct.

...note this: Bike ran very well before the kit.
FMF controller
Drilled airbox & K&N filter
Stock muffler opened up a bit and Powerbomb header
All smog/EXUP/Flapper gone, rtc.
TPS adjusted

...O.K.....we re-did everything.
Had a second pair of eyes and hands this time.
Made sure the cam sprockets and timing mark were spot on.
I definitely had one or two skipped teeth due to not properly engaging the cam chain tensioner the first time.

Spark - check
Fuel - check
Battery charged - check

Still...it won't start....I'm getting bummed.

Haven't done a compression check yet.
Tried with the FMF connected and also disconnected (out of the loop).

Thinking of trying the Aethena fuel module next.

By fuel, do you mean there is fuel in the tank, or did you verify fuel is getting to the cylinder? Could be a loose wire to the fuel pump, or maybe a bad fuel pump. I doubt it is the programmer.

Or if your cam jumped a few teeth, is it possible that you did some valve damage?

...well anything is possible of course, but it wasn't making any nasty noises when it was running, nor when it just died on the freeway.
I had my earplugs out to listen for weirdness.

Fuel in the tank, about 1/3rd full.
Checked the plug and it is wet.
The fuel pump makes noise and I did test it by running a hose from the tank to a jar and turning the key on.
It makes noise and fuel comes out.
Checked the plug for spark, yes, sparking.

dmmcd wrote:

Or if your cam jumped a few teeth, is it possible that you did some valve damage?

+1 I really think that this could be a possibility. If you have a compression checker, this will help you figure it out.

...I'm ass-pryin' it's not.
Atually only skipped one, two at the most.
Exhaust cam mark was off just a tad forward.

...well the ass-prayin' didn't work.
Compression test showed ZERO.

Pulled it down again.
Two valves have keeper damage, hopefully not actual valve damage but I suspect I'll have to buy at least one intake at $91...
plus new gaskets/keepers/shims.
Mistake all mine...

Good news is, the piston top looks perfect, maybe just the slightest mark from one intake valve.
Cylinder bore looks perf...

I am sorry to hear that. I made a similar mistake on my girlfriend's XT225. I forgot to tighten the cam sprocket bolt when I was putting it back together. It made it 10 miles until the cam bolt loosened enough to allow the sprocket to spin freely. I bent an exhaust valve in the process. That mistake only cost me about $46 in total. I went ahead and put new valve seals while I was in there along with a new valve.

Anyone know if the Athena head gasket is the same dimensions as the OEM gasket?

Rapid Dog wrote:

Anyone know if the Athena head gasket is the same dimensions as the OEM gasket?

Not if it's a big bore kit gasket.

...if anybody gives a hoot, got it all back together.
Used the Athena module.
The thing runs just fine I must say...more funner, nothing money can't fix.

good job man!

I'll be doing my Athena kit over the winter.. Also with a Power Commander 5 + Auto tune!

kinda pumped about this..

...I sent the FMF out to be reflashed.
The Athena fueler seems to be just fine/maybe better. No weirdness at all...