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Ride out today - few issues came up
Topic Started: Aug 29 2016, 10:04 PM (442 Views)
Munkee
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Earl
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I managed to get a decent ride out today for once, and managed to get a good run in great weather 😀

I was out with a mate who took his XR600, which is factory fresh with less than 1500 miles from new. Massive contrast between the two for what are, on paper at least, similar machines. The fit and finish of the Honda was much better, with everything feeling well engineered - could be down to how 'new' it is though. XR engine also felt much more civilised than the Rotax. However, the 604 was much more sophisticated in the suspension department and while I didn't notice much difference. My mate felt the CCM was definitely a faster bike. The biggest difference though? The XR seat is very comfortable, where the CCM seat is shockingly terrible!

A couple of issues came up though that I thought I'd throw out to the forum to see if there's any known issues:

My battery wasn't charging throughout the day, so by the end of the ride I had to kick start (left boot, not good!). I haven't put the volt meter across the terminals yet, so don't know how depleted it got.

My thoughts are:

1. Dodgy connection
2. Knackered stator
3. Knackered reg/rec (not convinced the one I have is the right unit anyway)
4. Knackered battery which just won't hold charge (possible - it's been flat before and I've had it on the conditioner more recently to keep the charge up)
5. Any combination of the above.

I'll check the battery charge being held, as well as the connections throughout, but are there any known common causes worth checking?

The other matter is the gears, which became difficult to select neutral, like it was jammed or something - needed a real shove to get out of first and generally just went straight through to second, missing the neutral point. Any common problems in this area or just another peculiarity?

as ever, all help and advice appreciated!

Steve
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Monty
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Charlie Big Banana's
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Obviously the first thing to check would be the connections, check pins are not green, clean up and spray with wd40 or simular, also check continuity of the plug,
next I'd check the charging voltage whilst running, should be in region of 14v, if still 12v ish, then reg/rect is knackered, never seen the charging windings go down, but you can check their continuity,
As for the battery, unless you have a battery load tester, I would leave standing and measure voltage in morning, then check during the day to see if the voltage stays the same.

But having said all that, I'd go with the reg failing.

I made a adapter plate for mine and fitted a 644 suzy reg, I've had no probs since fitting one, I have lunched several 604 units in the past whilst in Wales, dont think they like being submerged.
If it aint sharp I can play with it
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Munkee
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Earl
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Cheers Monty - I think the reg I have is from a 644 and had to make an adapted plate myself when I changed out the chopped up airbox.

I'll set to and see where I get to.
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jonny h
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this is how i roll!
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regards to the gear changing, only time iv'e had this, was when i did the Rallys with lots of lower speed technical bits, not happened since drilling the clutch basket though
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,C26 604e, Posted Image

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2wheels
Knight
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I cant find neutral with the bike running and stationary. Its not just difficult but impossible. It caj be found while still rolling up to lights and no problem at all when not running. Weird one.
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Sportax Racing
Anything & Everything ROTAX
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The clutch basket may be very grooved not allowing the plates to freely seperate. You may have a warped steel or broken friction plate. It may have been dismantled and assembled with incorrect size steels. 604's have 1mm thick steels but 1.25 and 1.5 are available. Too thicker steels wont allow the clutch to seperate properly either. The clutch springs dont fully compress which leads to clutch slip too..
Worth stripping and investigating..
www.sportaxracing.co.uk
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