Solved!!!
And it was…….a massive air leak!!!
Here’s what happened.
It has been my impression that the top rubber pieces on the throttle bodies, I’ll call them “snorkels”, were to remain on the throttle bodies. Every time I pulled the intake muffler off I left the rubber “snorkels” attached to the throttle bodies.
Not right.
The rubber intake “snorkels” should have been disconnected from the throttle bodies and left inserted into the intake muffler.
Keep in mind that I have had the intake muffler off more than a few times since we acquired Rotti back in 2012. Each time the “snorkels” were, I’ll say, long enough to push back into the intake muffler to make a sufficient seal.
When I did the brake bleed back in Jun of 2021 I did pull the tank and intake muffler off the bike to do some clean up and to keep any brake fluid from dripping on any surfaces. When I replaced the intake muffler this was the last straw so to speak, the “snorkels” had become so pushed down on the throttle bodies that they were no longer long enough to push into the intake muffler and create a seal.
The result…a massive air leak.
Both I and the Tech did an air leak test or two. Both of us sprayed the flammable fluid at the throttle bodies and the rubber manifold sealing the throttle bodies to the cylinder head. Both of us got negative results so a possible air leak was shelved.
While doing the nth test start, the shop Tech noticed the air muffler was very loose on top of the throttle bodies. That’s when he discovered that the “snorkels” were not sealing properly into the intake muffler. An air leak test with the flammable spray pointed towards the “snorkels” and the intake muffler told the story…a massive air leak.
All went back together with the “snorkels” properly seated in the intake muffler and Rotti began to correct itself as the Motronic learned the new air flow. By the third start she idled at the factory 1,050 rpms.
So…after a huge amount of testing and replacing and testing and replacing it was nothing more than an air leak.
This has been an experience, for sure, though I’ve learned a lot in both how Rotti works and how to diagnose problems she may develop.
I should have Rotti home by next weekend, the 18th of September. I’m considering throwing a “Welcome Home Rotti!” party.
Thanks to all who commented and provided moral support. It was appreciated.
And super thanks to Markus and Iron Horse Motorcycles in Tucson, AZ for finally sorting it out.
Deryle & Wanda Mehrten
Sierra Vista, AZ USA
And it was…….a massive air leak!!!
Here’s what happened.
It has been my impression that the top rubber pieces on the throttle bodies, I’ll call them “snorkels”, were to remain on the throttle bodies. Every time I pulled the intake muffler off I left the rubber “snorkels” attached to the throttle bodies.
Not right.
The rubber intake “snorkels” should have been disconnected from the throttle bodies and left inserted into the intake muffler.
Keep in mind that I have had the intake muffler off more than a few times since we acquired Rotti back in 2012. Each time the “snorkels” were, I’ll say, long enough to push back into the intake muffler to make a sufficient seal.
When I did the brake bleed back in Jun of 2021 I did pull the tank and intake muffler off the bike to do some clean up and to keep any brake fluid from dripping on any surfaces. When I replaced the intake muffler this was the last straw so to speak, the “snorkels” had become so pushed down on the throttle bodies that they were no longer long enough to push into the intake muffler and create a seal.
The result…a massive air leak.
Both I and the Tech did an air leak test or two. Both of us sprayed the flammable fluid at the throttle bodies and the rubber manifold sealing the throttle bodies to the cylinder head. Both of us got negative results so a possible air leak was shelved.
While doing the nth test start, the shop Tech noticed the air muffler was very loose on top of the throttle bodies. That’s when he discovered that the “snorkels” were not sealing properly into the intake muffler. An air leak test with the flammable spray pointed towards the “snorkels” and the intake muffler told the story…a massive air leak.
All went back together with the “snorkels” properly seated in the intake muffler and Rotti began to correct itself as the Motronic learned the new air flow. By the third start she idled at the factory 1,050 rpms.
So…after a huge amount of testing and replacing and testing and replacing it was nothing more than an air leak.
This has been an experience, for sure, though I’ve learned a lot in both how Rotti works and how to diagnose problems she may develop.
I should have Rotti home by next weekend, the 18th of September. I’m considering throwing a “Welcome Home Rotti!” party.
Thanks to all who commented and provided moral support. It was appreciated.
And super thanks to Markus and Iron Horse Motorcycles in Tucson, AZ for finally sorting it out.
Deryle & Wanda Mehrten
Sierra Vista, AZ USA
