Ignition/Carburetor Problem

[Klavdy]

Meh, Pat, just give them something else to look at,,,

http://www.liveleak.com/view?i=63b_1379002451

[Capn Ron]

I now know why Klavdy has "Super Hero" status on this forum...   

Cap'n Ron. . .

[Goody]

Looks like aluminium oxidisation . Are there any aluminium cables or connections in there?

[Goody]

Okay - update.

So I pretty much took the whole bike apart, checked all my connections (which were clean), checked all four plugs for spark (of which I got spark from all of them), got the battery load tested (which also had a fine charge).

So that left the CDI box...and as I unscrewed it, some white powder came out...and it looked like this:

http://imgur.com/sJM8mZD

...which I don't think is supposed to have that white powder in it. It looks like some serious form or corrosion.

Any ideas?

[djmarklong]

I don't know if there are any aluminum parts inside the CDI box. I tried to take the circuit board out of the box but it seemed it was glued in there or something.

On a different note, I did happen to notice something that probably shouldn't be in there...I took the CDI box out of it's mounting and noticed something rusted and metal underneath it...

http://imgur.com/wMkFjH0

so I pulled it out and found this:

http://imgur.com/688jCyP

What the heck?! I think this may have something to do with it. This drill bit or screw head or whatever it is is all rusted like it's been there forever. Anyone think this could've maybe fried the CDI box or something?

[Goody]

The item you found is a interchangable screwdriver head , it's probley from the bikes tool kit and has been dropped down there by accident when work has been carried out on the bike . It should definitely not be in there could have caused problems if come into contact with live parts or dissimilar metals such as aluminium .

[Goody]

The item you found is a interchangable screwdriver head , it's probley from the bikes tool kit and has been dropped down there by accident when work has been carried out on the bike . It should definitely not be in there could have caused problems if come into contact with live parts or dissimilar metals such as aluminium .

I don't know if there are any aluminum parts inside the CDI box. I tried to take the circuit board out of the box but it seemed it was glued in there or something.

On a different note, I did happen to notice something that probably shouldn't be in there...I took the CDI box out of it's mounting and noticed something rusted and metal underneath it...

http://imgur.com/wMkFjH0 hope this helps djmarklong

so I pulled it out and found this:

http://imgur.com/688jCyP

What the heck?! I think this may have something to do with it. This drill bit or screw head or whatever it is is all rusted like it's been there forever. Anyone think this could've maybe fried the CDI box or something?

[Woodsman]

Could be that you have an electrical issue alright. Good luck finding that and there are plenty lads able to help you there.
Reluctance to start in the morning combined with the smokey start could mean you have oil leaking down past the valve seals overnight? Sounds like once it's up and running it's fine. How many miles are on the clock?
Make sure your battery is fully charged and is good when you start it in the morning and do the coil mod, this will all help starting. If you've the old type starter consider getting the upgrade from RPM.
Sean.

[djmarklong]

Well, it seems the plot thickens on my FJ...

First - Sean, it's got around 30k on the clock.

So...after posting pictures of that corroded CDI box, I cleaned all that powder out and put the box back where it was supposed to go, and gave the bike a test run. It seemed like mostly everything was hunky dory at that point...everything was running well.

So, I decided since I had everything right there, I was going to put new screws on the caps of my carbs, since the ones that were on there were pretty worn out and I didn't want to have one stuck in my carburetor that I couldn't get out.

Anyway, I took the seat and gas tank off, put the new screws on, put the tank back on, put the seat back on turned the key, and...

...nothing. The key is in the is in the 'on' position, but I have no headlight, no horn, no turn signal, no dash lights, no starter, nothing. I do have the clock though, so there's that!

I literally changed nothing except for the screws on the carbs, and now the bike won't even think about turning on. Someone suggested I replace the fuses, so I did that, but to no avail. Maybe I forgot to connect some wires somewhere? I double-checked my connections, but there's always something I could have overlooked.

I'm pretty close to giving up and taking it to a shop. That's like...my last resort, so I'm hoping someone can give me something to check before I throw in the towel!

Also, thanks to all for your help thus far, you all have been so nice to help me with my what-seems-to-be-becoming-a-project bike.

[movenon]

Yea, it 20 plus years old and needs to be brought up to speed.  It's just a machine.... Make sure your Kill switch is in the run position, remove the seat, check the battrey connections and battery voltage just because. You jiggled something in that area. Check the starter relay and fuses..... You are probably close to getting it fixed.
George