Venting Probs 450 Rebel ?

[GearJammer]

Have been experiencing venting problems with this Rebel since getting it. Seems too high a fuel level in the gas tank & it'll either stumble at around 55 mph, cough a bit & then I'd reach down & switch the petcock from regular position to reserve & it'd be O.K.

Or sometimes, the bike would fire-up from being off, run for a few seconds & then stall out. After hitting the starter button for x number of times, she'll finally stay running & be O.K.

Many have suggested popping the gas tank cap when the stumbling happens & seeing if that makes any diference. It doesn't seem to do anything. Have also looked when the gas tank was off the bike & there's no vent line running directly from the tank to the EPA gear. But there is the breather vent hose coming from the cylinder head that runs to the breather seperator (charcoal cannister ?) & a drain hose from the seperator that has a plug in the end of it.

Today I removed the drain hose plug & left it out. Went for a good ride & experienced no problems (so far) If I place my hand at the base of the now open drain hose, can feel air "puffing" against my hand.

Does anyone know if removing the drain hose plug is the actual cure for this venting problem ? So far, so good...but just wondering if anyone else has experienced this problem & if so, how did they remedy it ?

(On a side note, after changing the oil & oil filter yesterday, there's still no oil leakage, so that's one positive note here :wink:)

[GearJammer]

Update & random thinking out loud....hehehe......

Took her out for an extended ride yesterday & still getting an intermittent stumble with power loss & backfire. Leaving the drain hose plug out none-the-less.

When she's running good, she's running GREAT! It's this intermittent problem that's getting to be annoying. Did a solid 25 mile run with absolutely NO problems. Then the temporary stumble/power loss/backfire thing. Stopped for lunch, she fired right up afterwards & had NO problems on the 25 mile ride home.

At this point, am going to live with it, continue to ride it & gradually attend to one thing at a time.

Popping the gas cap has zero effect when this happens. Haven't yet pulled & cleaned petcock or carbs, but will probably go thru the fuel system & airbox EPA mess at my leisure.

Am also considering that this "might" be an electrical problem. Fuel & electrical problems oftentimes mask themselves one for the other & yesterday it occurred to me that maybe it's a matter of a dicey electrical component heating up/cooling down type of thing.

Time will tell & will keep posting results over time as one thing after another gets checked off the list of possibilities. It's interesting how when she starts backfiring how the cages behind me start getting further away in the rear view mirror, LMAO! Was riding with a Bro who's got an '05 883 Sportster. Aside from the temporary stumbling incident, the 450 Rebel was RIGHT THERE at all times :lol:

Quick edit: The 883 has stock pipes, the Reb has the 12" EMGO Shorties. Tho' the Rebel doesn't "sound like a Harley", it's got an angry, "braappy" sound to it & definitely louder than the stock Harley pipes.

[GearJammer]

Been using the search engine to get a sense of what might be causing this intermittent problem. Apparently, it's quite common & found some similar possibilities on various boards around the Net.

Suggested causes/remedies (the short list of most common ones) :

Petcock needs cleaning
Plugs, wires, coil
Water and/or debris in carb float bowls
EGR valve (have to check the manual to see if this applies to the 450)
Air filter in need of replacement

Will start with a couple easy ones first, will drain the float bowls to see what comes out, replace air filter (a chance to utilize the air filter info that Snorey chased down)

[GearJammer]

Took her out again without having done anything to it. Used the reserve petcock setting & experienced NO problems today, ran like a champ. Hmmm....maybe it's the main petcock setting that's funky. Tell will tell...End of today's update from the Lazy Rider, too busy ridin' to tear into the list of possibilities, LOL!

[Chopper Rick]

I've had the same problem with my 450 that you've been experiencing but haven't had the time to check it out since mods to the bike have taken up my time. But for me it tends to happen most often during cool weather conditions.

[GearJammer]

Thanx very much, Chopper Rick...Hopefully we can compare notes as we both check this problem out as time allows.

Interesting enough, took a few hours' ride today & it was cold....*brrrr*, LOL! Using the reserve petcock setting & continuing to leave the drain hose plug out, only had one "little" burp & slight backfire all day. Other than that, she ran like a top, even doing some highway riding at 75 mph. Have also been sure to not completely top off the gas tank & have only been filling it until the fuel just covers the visible top of the tank tunnel inside the tank.

Listed the most common possibilities in an earlier post in this thread & am starting to think that in my case, it's a petcock that needs cleaning (for the main petcock setting) & possibly still some venting issues, tho' by removing the drain hose plug, it seems to be doing it less now. The air filters that I ordered haven't come in yet & that's yet another possible cause of this frustrating stumble, so will see if it improves after installing a new air filter & will be sure to keep you posted.

What mods have you done on yours ? (Trying to compare mods to see where we may be at with this venting thing) I've cut the pipes & installed EMGO 12" Shorties, but haven't messed with the air box yet, other than the removal of the drain hose plug. Our problems may be due to different causes, but it sure can help us both to compare & try to sort this mess out one item at a time. Frustrating, ain't it ? LOL!

[Chopper Rick]

Thanx very much, Chopper Rick...Hopefully we can compare notes as we both check this problem out as time allows.

Interesting enough, took a few hours' ride today & it was cold....*brrrr*, LOL! Using the reserve petcock setting & continuing to leave the drain hose plug out, only had one "little" burp & slight backfire all day. Other than that, she ran like a top, even doing some highway riding at 75 mph. Have also been sure to not completely top off the gas tank & have only been filling it until the fuel just covers the visible top of the tank tunnel inside the tank.

Listed the most common possibilities in an earlier post in this thread & am starting to think that in my case, it's a petcock that needs cleaning (for the main petcock setting) & possibly still some venting issues, tho' by removing the drain hose plug, it seems to be doing it less now. The air filters that I ordered haven't come in yet & that's yet another possible cause of this frustrating stumble, so will see if it improves after installing a new air filter & will be sure to keep you posted.

What mods have you done on yours ? (Trying to compare mods to see where we may be at with this venting thing) I've cut the pipes & installed EMGO 12" Shorties, but haven't messed with the air box yet, other than the removal of the drain hose plug. Our problems may be due to different causes, but it sure can help us both to compare & try to sort this mess out one item at a time. Frustrating, ain't it ? LOL!

You may be on to something as it pertains to the petcock/fuel valve. With me it would act up mainly if it was to cold outside or i would forget to turn the fuel valve in the proper position. It sounds like to me you might be looking at a fuel issue problem here, maybe dirt in the line or like you mention the petcock needs cleaning.

As for the Mods i've been doing, i made some custom rear fender struts that bolt from inside the fender so you don't see the bolts from the outside. put a Flander Drag Bar on & a set of bone risers, changed the rear fender & cut it down bobber style, will be going with a custom springer seat, custom brake pedal probaby fashioned after a foot. remove the shocks & replace with solid struts. change the oil dip stick cap to a cube ball or dice design, change the mufflers. I'm considing changing the gas tank to a bobber style. I've already made a points cover with a spade design. Sparto Tailight, no front fender, no chain guard, will make a custom gas cap & other ideas that i've been tossing around in my head. I was thinking about going with a kick start & a jockey shifter but it would probably requirer modifying the frame & going with a totally different motor. I still would like to do that, the kick start & jockey shifer but i would have to do alot of research to determine if it can be done. I will be painting the bike myself either flat black or satin. I like bikes that are hardcore & stripped down without alot of crap on it. In my house it's throw away the parts catalog & make your own parts if you can.

[GearJammer]

Sounds SWEET! Also like your ideas VERY much! You're turning it into a total bad-a** bobber!

Kickstart (man, I miss the kickstart on these new bikes) & jockey shift will take some research as you've pointed out. Please keep in mind that the gas cap needs to be vented, which kinda goes along with the venting problem overall. If you change out the gas tank entirely to another style that has gravity feed petcock(s), please remember that the vacuum port on the head will have to be blanked off (the port where the small diameter hose runs from head to stock petcock). Am considering keeping the stock tank & changing petcock to gravity feed & blanking off the port.

Used to use the cheapest flat black I could find, but got turned onto Ace Hardware brand BBQ Black, heat resistant to 1000 degrees type. Will use that brand from now on even tho' it's more pricey as it dries nice & even & offers a satinny finish. Also pretty durable.

As much as I like the lowered shocks from a 250, am considering going with solid struts since I'm leary off trying to pack a passenger with the lowered shocks & the probable bottoming out of the rear fender on the rear wheel. Solid struts would cure that problem.

And I agree with you that the venting problem on mine is probably related in good part to the petcock itself being funky.

[Chopper Rick]

Thanks for the heads up on the tank & venting issues.

[Chopper Rick]

Gearjammer, do you know of any tanks off of other bikes that can be used on the 450?

[GearJammer]

Not off hand. Haven't measured the tank tunnel or tried any other tanks on the backbone.

If you're a fan of "Frisco mounted", running along the top of the backbone, then just about any tank can be made to work. You'd simply have to fab a brace of sorts beneath the tank to keep it from tipping. Guess if the front & rear tank mounts were flush with the backbone, one could secure it by drilling into the backbone, but it wouldn't hurt to add a brace for extra security.

Regardless of tank choice, the other thing to keep in mind is adequate handlebar clearance while turning the forks full-range left & right.

Do you have any ideas of what style tank you might prefer ? I know you mentioned a bobber style...

[Chopper Rick]

Well the types of tanks i've been looking at are the Mustang Style for sportsters.

Something along these lines.

http://www.foghollow.com/cgi-bin/catalog_new.pl?fid=988645184.508071&query=Category%3DGas%252FAir%252FOil%26Description %3Dgas%2Btank%26PartNo%3D%26pagenum%3D1%26cgifunct ion%3DSearch%26submit%3DSearch&cgifunction=form


http://www.foghollow.com/cgi-bin/catalog_new.pl?fid=988645119.923044&query=Category%3DGas%252FAir%252FOil%26Description %3Dgas%2Btank%26PartNo%3D%26pagenum%3D4%26cgifunct ion%3DSearch%26submit%3DSearch&cgifunction=form

[cTc]

I've seen the 500 (cm) (cx) ? tank on a 450, and my favorite one was the vlx 600 tank on the 450. of course there were mods there for fitment but the looked good.

[GearJammer]

That's right. Had forgotten the VLX 600 tank that you'd mentioned before, CTC. Do you know if the fitment issues were only for mounting or did they include altering the tunnel ?

Always thought that the stock Rebel tanks looked somewhat like the aftermarket Mustangs (2nd link) & the 3 gal. capacity is a definite plus.

Chopper Rick, both of those style tanks you listed are probably available with flat mounts, both front & rear of tank, so they'd lay flat on top of the backbone if desired. If you're not into the Frisco style mounting, then it would be a matter of measuring the tunnels to see if they'd mount up the regular way without fabbing or not.

That 1st one has the interfacing mounting brackets in front that I've seen on vintage Sporty tanks, but there are also some Japanese copies that have flat mounts instead.

Same for the 2nd tank, typical Mustang. Some have the mount that rides over the backbone as pictured & have seen some with the flat mounts.

Either way, both styles would definitely work for that bobber look.

[Chopper Rick]

I've seen the 500 (cm) (cx) ? tank on a 450, and my favorite one was the vlx 600 tank on the 450. of course there were mods there for fitment but the looked good.

Thanks man for the infor. Do you happen know off hand if the 500 cm/cx tanks fit right on the 450 Reb or are there mods that need to be made?

[Chopper Rick]

That's right. Had forgotten the VLX 600 tank that you'd mentioned before, CTC. Do you know if the fitment issues were only for mounting or did they include altering the tunnel ?

Always thought that the stock Rebel tanks looked somewhat like the aftermarket Mustangs (2nd link) & the 3 gal. capacity is a definite plus.

Chopper Rick, both of those style tanks you listed are probably available with flat mounts, both front & rear of tank, so they'd lay flat on top of the backbone if desired. If you're not into the Frisco style mounting, then it would be a matter of measuring the tunnels to see if they'd mount up the regular way without fabbing or not.

That 1st one has the interfacing mounting brackets in front that I've seen on vintage Sporty tanks, but there are also some Japanese copies that have flat mounts instead.

Same for the 2nd tank, typical Mustang. Some have the mount that rides over the backbone as pictured & have seen some with the flat mounts.

Either way, both styles would definitely work for that bobber look.

Thanks for the infor. It sounds like i have several options to choose from.

[cTc]

I didnt get a chance to comb them, but the looked to fit pretty well. The VLX tank does not mount with the forward flance like the rebels, it mounts to rubber bushings inside the tunnell. I know there would be some mods there, but I think the 500 may mount the same as the rebel, but I cant say for sure.

[GearJammer]

This is an interesting subject. Alternate gas tanks & the degree of difficulty in mounting different ones can be helpful for lots of custom builders out there.

Remembered another point as regards Sporty & Mustang tanks. They're usually offerred with either shallow tunnel or deep tunnel. A shallow tunnel, when mounted normally on the backbone might still allow adequate clearance below the tank. A deep tunnel, when mounted normally, might place the petcock/fuel line dangerously close to the hot motor, in which case a Frisco style mount might be utilized to raise the petcock/fuel line heigth.

Points to consider:

Mounting issues
Handlebar clearance
Petcocks - Gravity feed & blanking off of vacuum port or keeping the vacuum actuated type
Petcock/fuel line clearance
Fuel capacity (not as critical with a high mpg bike, but something to keep in mind)

[Chopper Rick]

I didnt get a chance to comb them, but the looked to fit pretty well. The VLX tank does not mount with the forward flance like the rebels, it mounts to rubber bushings inside the tunnell. I know there would be some mods there, but I think the 500 may mount the same as the rebel, but I cant say for sure.

Thanks Chopper Town.

[Chopper Rick]

This is an interesting subject. Alternate gas tanks & the degree of difficulty in mounting different ones can be helpful for lots of custom builders out there.

Remembered another point as regards Sporty & Mustang tanks. They're usually offerred with either shallow tunnel or deep tunnel. A shallow tunnel, when mounted normally on the backbone might still allow adequate clearance below the tank. A deep tunnel, when mounted normally, might place the petcock/fuel line dangerously close to the hot motor, in which case a Frisco style mount might be utilized to raise the petcock/fuel line heigth.

Points to consider:

Mounting issues
Handlebar clearance
Petcocks - Gravity feed & blanking off of vacuum port or keeping the vacuum actuated type
Petcock/fuel line clearance
Fuel capacity (not as critical with a high mpg bike, but something to keep in mind)

This is great infor Gearjammer. Thanks again.

[Chopper Rick]

One other mod i forgot to mention that i'm considing doing with the 450 is a front springer. I mean if your going to go with the bobber look you might as well go all the way.

[GearJammer]

Oh yes, a springer front-end would definitely look sweet on there. I can picuture an old Harley wide springer, stock length to keep the bobber low 'n mean. That would require some work to get the right upper & lower bearings situated, fork stem length would have to be right, but it can definitely be done. I'm a firm believer in where there's a will, there's a way.

But bobbers were also built using the stock tube-type front-ends & can look very sweet as well. It's your "chopper vision" or in this case "bobber vision" :D and you can pretty much make it work.

[Chopper Rick]

"Oh yes, a springer front-end would definitely look sweet on there. I can picuture an old Harley wide springer, stock length to keep the bobber low 'n mean. That would require some work to get the right upper & lower bearings situated, fork stem length would have to be right, but it can definitely be done. I'm a firm believer in where there's a will, there's a way".

Now your talking Gearjammer. If all works out when i'm finished with the bike it will no longer look like a Honda but will look like a one off custom. Nothing fancy or mainsteam here, just an old school hardcore chopper.

[GearJammer]

"If all works out when i'm finished with the bike it will no longer look like a Honda but will look like a one off custom. Nothing fancy or mainsteam here, just an old school hardcore chopper."

I can dig THAT! :wink: Have looked at the modern "factory choppers", the Big Dog style & many others have that same aesthetic styling. Admittedly, they look pretty bad-a**, but are expensive & all look pretty much the same (My son doesn't dig the new ones at all, LOL!)

Your one-off custom will be extremely unique & much more appealing! To each their own, but I'll take a homebuilt chopper/bobber over any of the mainstream offerrings! :wink: The fancy new ones may have "styling", but the homebuilts have "CLASS".

[cTc]

anything springer would be cool, consider trying to get your hands a honda steed (vlx) front end, its sent everywhere in the world but the us, and comes with a factory springer. Go figure.

I am trying to locate one for my vlx.

Later

[Chopper Rick]

I hear you GearJammer. As for me, i'm not into building a bike from a kit nor do i care for those big fat rear tires. To me a true custom is when you can build that bike yourself with parts you find off of ebay or the savage yards. That's what building to me is all about . I don't need nor do i want my bike to look like something that most anybody can get from a kit. I mean don't get me wrong, if kit bikes are your thing than knock your socks off & have fun, that's what it's all about.

And for me it's alot more fun & challenging when you can take a piece of metal & mold it into something that only you have on your bike & no one else has. It makes a statement about you & what you ride. I can't get that out of a bike in a box.

[Chopper Rick]

anything springer would be cool, consider trying to get your hands a honda steed (vlx) front end, its sent everywhere in the world but the us, and comes with a factory springer. Go figure.

I am trying to locate one for my vlx.

Later

I'll have look into the vlx front end. Thanks for the heads up.

[GearJammer]

Very well said, Chopper Rick. Absolutely agree with everything you've said.

When the fat tire look first started, I thought they looked cool (even tho' they rob hp). But now, I'm just flat out tired of seeing them, LOL!

Your type of homebuilt is the one that'll make you feel much more gratified. You'll know your bike better as you'll know what went into it...by your own blood, sweat & energy. I LOVE to check out homebuilts up close & see every little one-off detail that the owner put into it. It's an amazing trip!

CTC, A stock VLX springer ? How cool is THAT ? Man, Honda must have been asleep at the wheel to not offer it over here where most of their bucks are made.

That's IT! We need to demand that Honda start selling those VLX springers over here...along with a new soft-tail version of the 250 Rebel, LMAO!

[Chopper Rick]

Gear jammer, since you dig homebuilds i highly recommend you order the dvd "Chopper Animals & Mayhem Machines Vol. 1 from www.choppahead.com

The dvd is all about the homebuilders who build bikes out of there garages, basements, living rooms or were ever they can find space. No fancy shops here or big bucks, these are about the guys with limit money & resources who work a full time job & come home & start building. These are the true builders who have a passion to just build something different. There bikes are made to be ridin. Check it out, i think you'll like it.

[Chopper Rick]

CTC, i forgot to ask you is there a specific year & make for the vlx springer i should be looking for?

[GearJammer]

Chopper Rick, Thanx very much for that link. Will check it out when I can....long day in town today, but.....

Here's some eye-candy for you & CTC:

http://www.honda-geneve.com/gallery/japan/steed.html

Guess the VLX Steed is/was ? available in both 400cc & 600cc. Some have the tube-type front-ends, some have the springer. Check this out :wink:

Looks good on the VLX, would look good on the 450 Rebel :D

(Have to sign-off for the night, later on, Brothers!)

[Chopper Rick]

Thanks Gearjammer for the link & infor on the Vlx.

[GearJammer]

My pleasure, Brother. There's some better pics that I found thru the search engine, but they were on other sites & didn't feel I should link to 'em without permission.

Until CTC mentioned it, hadn't been aware of the VLX w/springer. And in doing the search found the additional 400cc VLX version.

Not sure why Honda hasn't been selling these here. The only shred of a guess is that maybe they're worried about H-D trying to sue them or whatever. Or maybe H-D is PAYING them to NOT sell them over here ? LOL!

Check with ya later, want to check out that link you posted last night...

[GearJammer]

Checked it out & thanx again! SWEET chops & that DVD is definitely on a must buy list after the holidays!

Most of the chops are Triumphs (my main gig) & many are bobber style. If I'm not mistaken, the chop in the pic advertising the DVD has the same style springer as we've been talking about.

[Chopper Rick]

My pleasure, Brother. There's some better pics that I found thru the search engine, but they were on other sites & didn't feel I should link to 'em without permission.

Until CTC mentioned it, hadn't been aware of the VLX w/springer. And in doing the search found the additional 400cc VLX version.

Not sure why Honda hasn't been selling these here. The only shred of a guess is that maybe they're worried about H-D trying to sue them or whatever. Or maybe H-D is PAYING them to NOT sell them over here ? LOL!

Check with ya later, want to check out that link you posted last night...

Now trying to track one one of those springers down will take some work. If that fails, i may have to put one together with parts off of other springers which is not an easy task.

[Chopper Rick]

Checked it out & thanx again! SWEET chops & that DVD is definitely on a must buy list after the holidays!

Most of the chops are Triumphs (my main gig) & many are bobber style. If I'm not mistaken, the chop in the pic advertising the DVD has the same style springer as we've been talking about.

Your very welcome. The guy that build that Triumph chop your speaking of is actually Big Truth himself who runs the choppahead board. He's another one of those guys who works a full time job & than comes home & hits the shop where he builds some killer triumphs.

[Chopper Rick]

anything springer would be cool, consider trying to get your hands a honda steed (vlx) front end, its sent everywhere in the world but the us, and comes with a factory springer. Go figure.

I am trying to locate one for my vlx.

Later

Hey CTC, let as know when you track one down. I'll keep a lookout & see what i can find.

[GearJammer]

Much respect offerred to Big Truth & others like him. Remember hearing that of all licensed drivers, only 1 or 2% of those were also endorsed for m/c riding. And of THAT small percentage, only 1% actually built their own bikes.

"Now trying to track one one of those springers down will take some work."...Yep, it'll probably take some hunting for sure. If a person knew someone who lived in Japan or knew someone in the military stationed in that region, it'd probably be a piece of cake. And that stock VLX springer would probably be a relatively easy install on the 450 Rebel.

"If that fails, i may have to put one together with parts off of other springers which is not an easy task"...Agreed, tho' you'll see old, vintage wide springers on eBay now & then. I sold one some years ago for $100 & you can believe I wish I hadn't sold it now, LOL! The more complete the springer is, obviously the better. It's adapting it to another bike that can get challenging at times. Finding the right bearings top & bottom, insuring that the bushings on the rockers are sound for safety reasons, axle diameters, fork stem lengths & diameters, etc. Typical old Harley fork stem diameters are 1", British typically 7/8" and I've seen different diameters on Japanese. One Japanese fork stem from a crotch rocket had a fork stem diameter of 1" & it flared out to approx. 1 3/8" at the bottom, PITA if 1" was the maximum limit as that 3/8" would have to be shaved off & about the fanciest tools I've got in my shop are a sawzall & an angle grinder, so my methods of building are much more primitive, LMAO!

[Chopper Rick]

I'm with you there when it come's to primitive tools Gearjammer. It's time for me to start updating my tools & equipment real so. If you can build parts with primitive tools it'll be a cake walk with the new stuff.

I think one of the reasons you see so few people building there own bikes today is they watch the discovery channel & think that the only way you can build one is to have a ton of money. I always tell people to buy the cheapest bike you can afford & then learning how to fab & work on it.

[GearJammer]

"I think one of the reasons you see so few people building there own bikes today is they watch the discovery channel & think that the only way you can build one is to have a ton of money. I always tell people to buy the cheapest bike you can afford & then learning how to fab & work on it."...Good point & good advice on your part. Most people only see the fancy stuff on Disc. Channel & don't realize that there's some guys out there doing it the old way. Not as "colorful" maybe, but dang sure more "real".

"Indian Larry" remains to be my favorite of the ones who made it to well-known status. He'd have been doing what he did whether the fame came his way or not. Doesn't get more real than that.

(Posted a link on the General Chat board you might want to check out :wink: )

[Chopper Rick]

Indian Larry was one of my all time favorite builders too. I credit him for getting me into the hobby of learning to build & fab. He was a true inspiration to me & i'm sure to countless others.

[GearJammer]

Minor update on the venting problem as I try to figure this out. Once the weather warms up, will have to try to nail this down somehow, but in the meantime am trying to learn to live with it, tho' it IS starting to try my patience, LOL!

My son came down for Christmas (day after, I won't ride holiday eves or the actual holiday day) & went riding with us. I rode the chopped Trumpet & let him use the Rebel, told him to keep his eyes open for the obvious road hazards that hand out tickets, but other than that to just have FUN! He really enjoyed riding the modified Rebel, by the way :wink:

Back on topic, if I'm anywhere's near close to figuring this out, have gotten it narrowed down to two possibilities:

1) The main petcock setting being useless & in need of cleaning, so am running it strictly on the reserve setting.
2) Fuel level in gas tank doesn't want to be too full, have only been adding until the level is just over the visible tunnel inside the gas tank.

While we were riding, he only had one brief occurrence at around 55 mph where the bike stumbled a bit, backfired a few times, but it cleared up & we kept on trucking.

Took the Rebel out myself about a week later & when gassing up, wanted to round off the $$$ amount for the credit card receipt & added maybe ten cents more worth of fuel, tho' the level still wasn't close enough to being "topped off completely". Rode about 25 miles to my first stop with no problems whatsover. Tried to fire it up again & no dice! Sat in the parking lot for 45 mins. :evil: , alternately trying to fire it up, then taking small breaks so's not to overdo it on the starter. When this happens, it's always a concern as to whether the bike is going to start before the battery gives out. Also, during this 45 min. "break", had popped the gas cap several times & for the first time ever, could actually hear the gas cap venting when put back on, which I'll take as a good sign.

FINALLY got her fired up, went about the day & no additional problems at all.

Went out again yesterday, made sure that I kept the fuel level well within what seems to be the safe area & had absolutely zero problems all day.

Summary based on experimentation thus far: If I use the reserve setting only & keep the fuel level just over the tunnel inside the tank, the problem is either very brief & minor or non-existent.

On a side note, it was cool to have someone else ride the Rebel so that I could get a better sense of how the EMGO 12" Shorties sound. The Trumpet has straight pipes & is definitely loud (tho' not overkill) & riding alongside the Rebel, could easily hear the Rebel pipes. He'd purposely fall back a bit now & then, then give her a blast to catch-up & even over the sound of the Trumpet pipes, had no problem hearing him coming up from behind. The Rebel pipes have a distinct, angry "b-r-a-a-P-P" to 'em. :wink:

[GearJammer]

Not much new to report other than a 3rd ride without incident, no stumble, no problems.

Fuel level definitely seems to have something to do with it (at least in my case) Having the use the reserve setting on the petcock also indicates that the main setting is funked up. So far, so good, liveable, until the reserve setting gets clogged up & then will have no choice but to clean the entire petcock, LOL! Anyways, for right now, "if it ain't broke, don't fix it" works for me :wink:

[GearJammer]

Latest up-date:

One page 1 of this thread, had listed the most common causes of this stumbling/backfiring/venting problem. "Air filter in need of replacement" was one of those items.

Recently adjusted & lubed the final drive chain, checked the plugs & installed a new air fllter (first air filter change since owning this bike)

We went riding today for the 1st time since doing this maintainence & the Rebel ran like a friggin' champ!

Still using the reserve setting on the petcock, still keeping fuel level just above the tunnel inside the gas tank & still leaving the crankcase vent hose plug out. Now with the clean air filter in there, everything seems fine so far :wink:

One of my riding Bros was on his '05 883 Sporty & he tends to get on it a bit going down the road. This Rebel had absolutely no problem keeping pace with him. Man, I'm in no hurry as I've got the other project chop to attend to, but DEFINITELY going to be keeping my eyes open for another 450 at the right price :wink:

$800 for an '86 Rebel that keeps pace with an $8000+ '05 883 ? What's not to like ? LOL!

[GearJammer]

Up-date:

The air filter element change seems to have cured the stumbling/backfiring prob.

Realizing that the new (clean) air filter is no doubt allowing more air into the air/fuel mixture, I want to keep checking the plug reads periodically to insure that the motor isn't running TOO lean. Will keep posting results as I have them.

[uneasyrider]

Been using the search engine to get a sense of what might be causing this intermittent problem. Apparently, it's quite common & found some similar possibilities on various boards around the Net.

Suggested causes/remedies (the short list of most common ones) :

Petcock needs cleaning
Plugs, wires, coil
Water and/or debris in carb float bowls
EGR valve (have to check the manual to see if this applies to the 450)
Air filter in need of replacement

Will start with a couple easy ones first, will drain the float bowls to see what comes out, replace air filter (a chance to utilize the air filter info that Snorey chased down)

Hey GearJammer: Give Jack a call re. this problem, he seems to have solved the same problem on his 450 by changeing out the CDI. Give him a call and he can explain it to you.

Howard

[GearJammer]

Thanx, Howard...

No denying that Jack knows his stuff & has been helpful to many, many Rebel riders, so will definitely keep it in mind. Thankfully, the latest approach in changing out the air filter element seems to have remedied the problem....so far, so good, just keeping an eye on it & everything seems fine for now.

[GearJammer]

O.K., finally got brave enough to try to main petcock setting today. No problems whatsoever. Feel confident that it was a dirty air filter element all the while, tho' theoretically it could have been any of a number of things.

The essential resolvement (at least in this case) involved removing the crankcase vent hose drain plug & leaving the plug out. This seemed to lessen the problem, tho' it still showed up, just less frequently & less pronounced.

Changing the air filter element definitely put the icing on the cake! Zero problems since then.

Thanx to all who offerred their support & advice. :wink:

[Chopper Rick]

Congrats GJ, your persistence payed off for you. Glad to hear you iron out the problem.

[GearJammer]

Thanx, Chopper Rick! It sure gave me a run for my money, LOL! Remember being stranded in a parking lot for about 45 mins. 'cause she'd fire & then die until I finally got it to catch & keep running. I was sweating bullets as to whether or not the bike would fire-up before the battery charge gave out.

Now, she's running like a top & getting a LOT of use :D

Edit: Chopper Rick, did you check out that red & black 450 bobber pic in the Cool Mods section ? Man, that Rebel is one of the best I've seen & really has me wanting to do one up similar to that.

[Chopper Rick]

"Chopper Rick, did you check out that red & black 450 bobber pic in the Cool Mods section ? Man, that Rebel is one of the best I've seen & really has me wanting to do one up similar to that."

GJ, the red & black bobber i have seen before. I've been trying to locate the email addy & name of the owner so i can ask him some questions about it but i haven't been able to find it yet. My 450 rebel mods are similar to that bike with a few personal touches of my own.

chopper rick

[GearJammer]

Very cool, Chopper Rick! Keep on keepin' on with your project, you'll get there. It'd be cool if the builder could be located for some inside info, that one has been printed out here as an inspiration & motivation.

Not only looks SWEET as can be, but I'll bet he's pushing close to 44-45 hp after opening up the pipes & losing the EPA gear.