Air compressor system debacle 86 Aspencade


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Goofaroo
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Air compressor system debacle 86 Aspencade

Post by Goofaroo »



I am pulling my hair out trying to fix my air system! Nothing is happening with the bike in neutral, on the center stand, and the key on. I have checked and greased the fuse and the neutral light comes on. So far I have removed the switches on the lower right side of the fairing, diassembled them, cleaned and greased them,and checked them for continuity. I haven't reinstalled them yet but they work as new.

I have been doing research online and I found that the black and yellow wire and the black and brown wire should be hot with the key on. Now when I put my test light from ground I get a click somewhere in the compartment. I believe that it comes from the tall cylinder with the rubber cap that is right in front of the selector switch.

I found online a reference to removing the compressor and as far as I know it is the larger unit in the rubber housing in the front of the compartment. I have unhooked the rubber tabs and tried to remove it but the hose that goes to the right and down won't let me pull it out. I'm actually not sure how I will get it back in. Lol

What I am trying to do is make the pump serviceable so that I can adjust the rear shock and add air to tires. I would like to remove all of the hoses for the front forks and cap off the manifolds as needed. I have attached some pics showing the current status. Any help to get me moving forward would be much appreciated. I would like to get the pump out so that I can service it and eliminate the lines to the front.

















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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Hi that looks to be slightly different system to my 86 aspy, mine doesnt have a hose running along the top of the solenoid like shown in the second picture. the manual makes seem like a 10 minute job, its isnt its tough to get out, and unfortunately even worse to get it back in.

the only way i did it was clear everything out in front of the pump, I disconnected the two back and front hoses, took out the switch, the front cover, and the whole solenoid set up. after pushing in the two rubber nipples holding it to the frame, and lot wriggling it did come out.

replace the dessicant and filter this stuff breaks down and clogs the pump, mine was quite a mess.

Putting back in took two people I put a light lubricant on the two rubber nipples. and tied a bit of nylon to each one. I ran the nylon through the holes in the frame, and while a friend pushed the pump back in,I gently lined up the nipples and pulled them through. it took a lot of wriggling around though.

good luck.

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Goofaroo
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1987 Kawasaki KDX200
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

I appreciate the reply. I've pretty much figured I'm going to go ahead and take everything out of that compartment. Then I can test and service the whole mess. They don't make it easy.

My thinking is that I can just cap off the outlet to the front at the manifold and then disable the front selector switch. Does that sound like a plan or am I missing something?

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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Goofaroo wrote:I appreciate the reply. I've pretty much figured I'm going to go ahead and take everything out of that compartment. Then I can test and service the whole mess. They don't make it easy.

My thinking is that I can just cap off the outlet to the front at the manifold and then disable the front selector switch. Does that sound like a plan or am I missing something?
well I think if you intend not to use air in the front, you may need to change the springs, because my guess would be (and its only a guess is that the front would be pretty soft without air and OEM springs.

too disable, I think you would need to block air from the pump, or the switch could leak a little air wether you want it too or not. I guess the easy way would be to block the hose connector (one of the two shown in your picture) or perhaps the upper switch channel in the switch.

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Goofaroo
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

I've already got new fork springs. I'm speculating that blocking off the front air hose outlet and clipping off the tabs that activate the front valve core and power switch would be the simple fix. i don't know if it would hurt anything but I don't want to be able to power up the compressor with the "front" switch.

Of course at this point I'd like to be able to power up the compressor with any switch!

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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Goofaroo wrote:I've already got new fork springs. I'm speculating that blocking off the front air hose outlet and clipping off the tabs that activate the front valve core and power switch would be the simple fix. i don't know if it would hurt anything but I don't want to be able to power up the compressor with the "front" switch.

Of course at this point I'd like to be able to power up the compressor with any switch!
Yeh thats a pretty sound idea I reckon, I suppose too if you took off the plastic buttons and exposed the valve buttons a little glue on the top one wouldnt hurt.

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Goofaroo
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

Success! I just got the pump out!

Also, before I took it out I wired up all of the freshly serviced and tested switches and sure enough the compressor kicked on and the temp gauge displayed front and rear pressure. Also when I hit the decrease button the solenoid clicks and sounds like it is opening the valve.

I'm not sure what the taller device next to the shorter solenoid does and I forgot to check it before I took everything out. Anyone know what it does? It appears to be a sealed unit that can't be serviced.

I'm going to service the solenoid, the drier, and the pump and then figure out my strategy for disabling the front fork system.

Also, I couldn't get anything to happen hitting the "air outlet" button for airing up tires and such. The switch have been serviced and is working but nothing happens with the key in the on or accessory position. I couldn't try it in the park position because I have my handlebars hanging from the cables and wires since I'm replacing the steering head bearings. Does anyone know if it only works in park?
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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Goofaroo wrote:Success! I just got the pump out!

Also, before I took it out I wired up all of the freshly serviced and tested switches and sure enough the compressor kicked on and the temp gauge displayed front and rear pressure. Also when I hit the decrease button the solenoid clicks and sounds like it is opening the valve.

I'm not sure what the taller device next to the shorter solenoid does and I forgot to check it before I took everything out. Anyone know what it does? It appears to be a sealed unit that can't be serviced.

I'm going to service the solenoid, the drier, and the pump and then figure out my strategy for disabling the front fork system.

Also, I couldn't get anything to happen hitting the "air outlet" button for airing up tires and such. The switch have been serviced and is working but nothing happens with the key in the on or accessory position. I couldn't try it in the park position because I have my handlebars hanging from the cables and wires since I'm replacing the steering head bearings. Does anyone know if it only works in park?
Yep only works in park, congrats on getting it going good luck

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Goofaroo
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1985 Honda XR350R
1971 Honda CT90
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

Thanks! I'll be really glad when I get this pump project out of the way so I can keep going on the brakes and suspension.

Here's a shot before I put them in the toaster oven.
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Goofaroo
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

And fresh out of the oven
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Goofaroo
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1987 Kawasaki KDX200
1985 Honda XR350R
1971 Honda CT90
1984 Honda NH125 Aero
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

Woo hoo! I got the compressor system reinstalled and everything seems to be working. I aired the shocks up to their maximum pressure according to the gauge on the dash and it has held steady for a couple of hours so my shocks are apparently not leaking too badly.

Unfortunately when I got done I still had two wires that I didn't plug in. They are on the part of the harness that goes up to the compressor motor. They are light green with a black stripe and there is a male and a female. I don't recall if they were hooked up before but everything seems to work with them unhooked. Does anyone have any idea what they go to?
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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Goofaroo wrote:Woo hoo! I got the compressor system reinstalled and everything seems to be working. I aired the shocks up to their maximum pressure according to the gauge on the dash and it has held steady for a couple of hours so my shocks are apparently not leaking too badly.

Unfortunately when I got done I still had two wires that I didn't plug in. They are on the part of the harness that goes up to the compressor motor. They are light green with a black stripe and there is a male and a female. I don't recall if they were hooked up before but everything seems to work with them unhooked. Does anyone have any idea what they go to?
I'm taking a guess here, have you tested the compressor in park as well, thats the bit that lets the compressor pump tires up, it may have something to do with that

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Goofaroo
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1985 Honda XR350R
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

Good idea. I'll try that tomorrow.

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Goofaroo
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1971 Honda CT90
1984 Honda NH125 Aero
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Re: Air compressor system debacle 86 Aspencade

Post by Goofaroo »

I can check the air system off the list! This morning I turned the bars and set the switch to the park position. Then I checked for power at the orphaned wires and sure enough one of them had power. I took the speaker, the vent, and the vent duct back out so that I could figure out where to plug in the two green wires. I found nothing. So then I started looking at the rest of the wires and sure enough I saw two wires that matched in the bottom of the compartment. I had not connected the momentary switch that turns on the compressor in park. I hooked them up and the compressor now works in park. I put the ductwork and speaker back in and I am DONE with the air system.

In reality, I probably could have just serviced the switches and called it a day but now I'm pretty confident that my air system will be good to for quite a while. On to the next project!

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Re: Air compressor system debacle 86 Aspencade

Post by thrasherg »

Sounds like a lot of work, but should give you a lot of "peace of mind" when riding!! Also with it being winter you would have got bored if you didn't have all this to keep you busy!! :D

Gary

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oldishwinger
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Re: Air compressor system debacle 86 Aspencade

Post by oldishwinger »

Goofaroo wrote:I can check the air system off the list! This morning I turned the bars and set the switch to the park position. Then I checked for power at the orphaned wires and sure enough one of them had power. I took the speaker, the vent, and the vent duct back out so that I could figure out where to plug in the two green wires. I found nothing. So then I started looking at the rest of the wires and sure enough I saw two wires that matched in the bottom of the compartment. I had not connected the momentary switch that turns on the compressor in park. I hooked them up and the compressor now works in park. I put the ductwork and speaker back in and I am DONE with the air system.

In reality, I probably could have just serviced the switches and called it a day but now I'm pretty confident that my air system will be good to for quite a while. On to the next project!
nicely done congrats.



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