Shutting down in this Texas heat.

[Ffmedic166]

Please before anyone gives advise read what I written, i noticed albeit you guys mean well some tend to not read or underwhat is said and advise to do the same things mentioned in posts. Im off my soap box now! LOL

1996 GL1500A with less than 100k on odom.

Week ago was riding and hating this Texas heat when as i twist the trottle to speed up it hangs and does not go faster. So i figured maybe i picked up some trash in the tank. So I downshift and it advances but now at a higher RPM. Acted as though it was maxed out when in final gear. I stop at a gas station and fill up, i noticed after do some math i only got 15MPG...shocked to say the least. So I get back home and i dump some seafoam in her and let her run and idle for a bit and shut her off so the seafoam can maybe clean up any issues from sitting quarter of the year. Previous from sitting the carbs were rebuilt and synced. I went ahead and installed new plug when i started riding this past month or so. So its not the plugs!

Couple of days later after bringing the bike home and hot soaking the seafoam thru the carbs I rode around and did some errands, she ran like normal till i was just under half a tank. I am going about 40MPH when this time i give it some gas it like hitting a wall and the bike SLOWLY slows down till about 30MPH. I shifted 2 down and raced it back up and didnt seem to fix the issue. Was still in a stall per say and was about to pull to side of road. I was close to gas station so i kept driving but now I am in traffic and its in 1st gear...no issues idling like it should and when i move up with traffic it does not give me any issues. I make it to gas station and filler back up. AGAIN 15MPG, this time i am stressed out, hot and burning up from the heat of Texas and i heavy handed some seafoam and filled up the gas tank. I ride home and not one issue. But this time I am not liking the **** mpg and the inconsistency in the fuelling issue, what else could cause the lack of power. So I am not messing around this time. I ordered a new fuel pump, petcock and i got a paper air filter (Has a K&N filter). They came in yesterday and i installed and replaced everything. It seemed sluggish with the revs from the paper filter since more restrictive...why it would make a difference in runabily in a negative way when having a KN Filter is beyond me but i have read some have issues. So i cut out the bull crap and just run this paper one.

So I live in the Fort Worth Texas area and there is a bypass or highway called 820, i decide to see how she does by riding the while loop. I get though majority of and the bike is running smooth and actually seems better riding wise and running. I give it some gas in fifth, though its no rocket but it steady pulls and i achieve 75MPH. Then it just stops advancing or maintain speed. I down shift. Nothing I losing speed and fast and cars are trailing me. So i hazard my way to side of the road and its not wanting to run, i pop the clutch with the few mph i am going and nothing... So there I am sitting on side of the road and i shift to neutral and start to try to crank the bike up. It cranks but it wont run. This is new now. So i check the kill switch and its in the on position, out of gear and look at my amp meter and its 13.6 volts so it has the power to crank and give spark yet its acting like no gas.

NEW Fuel Pump Petcock and it has a month old fuel filter (Its a white non see through filter so i cant tell if gas pump into it) after about 5 mins i try cranking agian and it fires up and runs. So i sit there and idle casue I am thinkning its a thermal breakdown of something cause it runs till i guess something gets to warm/hot and shuts down. Five more mins and the temp gauge is moving toward hot and fans are on (No was not over heating) but is hotter then when i am moving down the road. Still bike sits and runs good. So i set out and I am about 12 miles from home. I give it the beans, and she gets going. I get three miles down the road and she shut down on me. So back on the side of the road... same thing! bang on the kill switch hoping that maybe that is my issue no dice. She just cranks over but does not want to fire up to run. So I figured well the kill switch maybe messing up so i wait and wait and wait some more. Cranking and cranking and i am worried i am going to drain battery. So i hop off the bike and pull seat...cant tell if fuel is flowing and if getting spark. I check my connections and feel on the tank and everything seems okay. I even undid the gas gas and left it sitting on top of the inlet. I cranked some more, few times it seemed like it was going to start up, not sure since indy 500 and the car flying by i can hear ****. i watch the tach and feel till i sense the rumble of the bike and rpms come up. It final running again. So this time i dont let it just sit and run i merge into traffic to get as close to home i can.

I have been having lean pops lately and so it seems to be acting up now with the lean pops, but this time i can hear it popping in my air box. a few times. I make it home and gun it around my neighberhood a few times. NO issue but a few exhuast pops and maybe a lean pop in air box. It does not shut down or anything and runs good. I park in my drive way and let it just idle, it gets to the point the static air and the fans working that it get toast hot the needle flirting with the high side and still i let it run. I left it like this for 20 mins and then hopped on it and rode it around the street couple more times. no issues. Parked look at the kill switch and admired how clean it was inside and even tighten more on the screws, they were not loose but with a little effort i was able to tighten down on them just a smidge.

Thanks for staying with me to the end! I know that its alot but I had to give detailed of whats going on. I have the battery voltage to run the bike, new pump, petcock, filters and even a recent oil change. WHAT IS THE ISSUE??? I cant replicate this crap and I have a planned tripped to colorado end of this week. so its paramount that i get this figured out.

Please steer me to ideas on what it is or could be!

[Rambozo]

Did you open the fuel cap when it wasn't running to see if it was vacuum locked?
The poor mileage makes me want to look for fuel leaks. Pumping fuel into that engine to get 15 MPG should be making black smoke and sooting up the plugs, so maybe an external leak. Have you checked the fuel pressure while riding? That can tell you a lot.
The pulse generators are known to have heat issues when they fail, but that really doesn't fit your symptoms. Not to say you might have more than one problem.

[Ffmedic166]

Did you open the fuel cap when it wasn't running to see if it was vacuum locked?
The poor mileage makes me want to look for fuel leaks. Pumping fuel into that engine to get 15 MPG should be making black smoke and sooting up the plugs, so maybe an external leak. Have you checked the fuel pressure while riding? That can tell you a lot.
The pulse generators are known to have heat issues when they fail, but that really doesn't fit your symptoms. Not to say you might have more than one problem.

I released the air in the tank, and did leave it off. But even sitting just idling and also rising around i put it back on when i was home and it did shut off. When i rode home the last time i left the cap off just resting on the tank inlet. This has been a new and acute issue, as ive not experienced long term and to see what does or does not work. I was hoping that someone might have experienced similar stuff.

Tomorrow i have plans to do the same route and see if it does it agian and if it does if its near and around same place as last time. That will give me a more base line. I have not looked in manual or done much in way of seeing how hard it would to be change out the PG. Are they hard and time consuming? and better yet are they are to get from Honda or parts place?

When you say fuel pressure while riding are you talking about removing gas cap while riding down the road?.. if so i have. but that was done today and during time it was not acting up. So not sure if it made a difference. from what i can tell the cap is acting normal like the other gl1500 i had and what this one has always done and that is it hisses when you remove. The previous plugs when i received the bike from my father had left bank black and sooty and ran much better with new plugs. I am about 100 miles now at half tank. so its better with the longer ride.

[Rambozo]

I released the air in the tank, and did leave it off. But even sitting just idling and also rising around i put it back on when i was home and it did shut off. When i rode home the last time i left the cap off just resting on the tank inlet. This has been a new and acute issue, as ive not experienced long term and to see what does or does not work. I was hoping that someone might have experienced similar stuff.

Tomorrow i have plans to do the same route and see if it does it agian and if it does if its near and around same place as last time. That will give me a more base line. I have not looked in manual or done much in way of seeing how hard it would to be change out the PG. Are they hard and time consuming? and better yet are they are to get from Honda or parts place?

When you say fuel pressure while riding are you talking about removing gas cap while riding down the road?.. if so i have. but that was done today and during time it was not acting up. So not sure if it made a difference. from what i can tell the cap is acting normal like the other gl1500 i had and what this one has always done and that is it hisses when you remove. The previous plugs when i received the bike from my father had left bank black and sooty and ran much better with new plugs. I am about 100 miles now at half tank. so its better with the longer ride.

Ok, not a fuel tank vacuum issue.
PG would be a no spark issue, not a no fuel issue. And would not change your mileage. Have you checked for fuel and spark when it dies and won't start?
To check fuel pressure, you need to hook up a pressure gauge and zip tie it somewhere you can see it while riding.
Your symptoms sure sound like a lack of fuel. As you lose fuel flow, your power will drop off. No spark is more of an all or nothing issue.
Any strong fuel smell while riding or sitting with the engine on or off?

[FM-USA]

It's rare these days... Vapor Lock?
You say it cools down it'll start & run.
Take a spray bottle of cold water, run it until it acts up, pull over & spray the hoses just rearward of the carbs.
IF that's not it, you've eliminated one possibility.

(fingers crossed) That's it.

[Ffmedic166]

I released the air in the tank, and did leave it off. But even sitting just idling and also rising around i put it back on when i was home and it did shut off. When i rode home the last time i left the cap off just resting on the tank inlet. This has been a new and acute issue, as ive not experienced long term and to see what does or does not work. I was hoping that someone might have experienced similar stuff.

Tomorrow i have plans to do the same route and see if it does it agian and if it does if its near and around same place as last time. That will give me a more base line. I have not looked in manual or done much in way of seeing how hard it would to be change out the PG. Are they hard and time consuming? and better yet are they are to get from Honda or parts place?

When you say fuel pressure while riding are you talking about removing gas cap while riding down the road?.. if so i have. but that was done today and during time it was not acting up. So not sure if it made a difference. from what i can tell the cap is acting normal like the other gl1500 i had and what this one has always done and that is it hisses when you remove. The previous plugs when i received the bike from my father had left bank black and sooty and ran much better with new plugs. I am about 100 miles now at half tank. so its better with the longer ride.

Ok, not a fuel tank vacuum issue.
PG would be a no spark issue, not a no fuel issue. And would not change your mileage. Have you checked for fuel and spark when it dies and won't start?
To check fuel pressure, you need to hook up a pressure gauge and zip tie it somewhere you can see it while riding.
Your symptoms sure sound like a lack of fuel. As you lose fuel flow, your power will drop off. No spark is more of an all or nothing issue.
Any strong fuel smell while riding or sitting with the engine on or off?

Well from what I was able to see it seemed to be getting fuel, not verified 100%. The previous two times I would say yes to fueling issue…hence why I bought new pump. But today was an instant no power just cruising at speed then bog of no power and instant no idle when clutch was pulled in.

At times I feel it run rich before all this but not as bad my previous bike. I will say that mpg has always been issue just never calculated lately cause I just started riding around again and figured all the stop and go and getting on it was eating my gas…but didn’t think it was as bad as 15mpg. At this point I don’t see it being a fueling issue. I am starting to think and worry that it might be thermal break down of PG. I haven’t verified it though but I could I guess tomorrow take the plastic off and carry spark plug socket so in case it does do it I hook up my spark tester.

Do you think maybe it was the kill switch and it was just loose enough to mess up? I bet dollars to donuts now that when I go test it that everything will work right and when i am hundreds of miles away the bike will act up again when on my Colorado trip.

Another interesting thing though is the lean pop in air box.

[Andy Cote]

Sorry I don't have the magic solution for you.

IIRC, the K&N removes the factory seal for the air filter box. You need to install this with the new paper filter.

With this horrible gas mileage, is it possible you are running out of gas?

I'm leaning toward ignition system; ECM, pulse generators, etc. Does not sound like kill switch/ BAS type failure.

I seem to remember someone with these same symptoms a couple years ago. Maybe a topic search.

[Ffmedic166]

If it were thermal wouldn’t it shut down just idling when getting hot?

[Ffmedic166]

Ok, not a fuel tank vacuum issue.
PG would be a no spark issue, not a no fuel issue. And would not change your mileage. Have you checked for fuel and spark when it dies and won't start?
To check fuel pressure, you need to hook up a pressure gauge and zip tie it somewhere you can see it while riding.
Your symptoms sure sound like a lack of fuel. As you lose fuel flow, your power will drop off. No spark is more of an all or nothing issue.
Any strong fuel smell while riding or sitting with the engine on or off?

Ok, so i gave it a spin today. Doing the same route I almost made it home till it shut off. I has fuel and even spark. It fired right back up after a couple mins and was able to get closer to home till it shut down agian. Agina i check spark and fuel. Still good! So i am stumped, so i got home and pulled plugs out Right as you sit on bike bank of plugs look newish and great...one had a pinkish look on the electrode. The left bank all were black and dry sooty deposit. SO rich on one side. No good. I checked compression. Here is as follows:

Cylinder/Bank
1Right - 175psi 2Left - 190psi
3Right- 175psi 4Left - 140psi
5Right - 170psi 6Left - 170psi

From what i can see cylinder 4 has a issue since its lower compression compare to the rest. I am more worried about the whole left bank being to rich compared to the other. I shot some MMO and reran compression test and manage to get a tad better result and a hell of a mess. While messing with plugs and doing the testing i ran the engine some more and noticed it was running weird and so i gave it gas and it stumpled and died. FINALLY i was able to reproduce the issue at home. Did it make a difference....um no! I looked at the clear gas filter and noticed it was still full of gas. Thats good right? I disconnected the hose from the petcock feed line to carbs and trace amount of fuel dribbled out. I crank over the engine and to make sure fuel was getting past the petcock...NOPE! But at the same time of this the sight glass for the fuel you can watch the fuel go down..strange. So i wiggled or tapped the wires on the fuel tank and the filter filled back up and started pumping out the petcock so i put the hose back on and the bike started running again. five mins later and same thing happens. i check the wires and everything shows 11.5 to 12.3 Volts yet no fuel was pumping. Now i am thinking this new pump is bad. WHat you think?

I bypassed the petcock and check wire connections on the pump and its been idling and holding fuel. I am confused. Why would it shut down on the highway and fuel still be in the sight glass and get spark but wont run? Could it be possible its over flooding the carb even while riding and it shuts everything down? I am at a lost now and i am 95% sure now i wont be taking my bike to Colorado. I feel overwhelmed and need help.

[Rambozo]

That is why I advised riding around with a fuel pressure gauge. Makes it pretty easy to troubleshoot fuel issues. I would say based on the plugs you have a problem with the left carb. Likely a stuck or leaking float valve. All that extra gas has washed the rings on that side and is probably responsible for the low compression. There is a good chance it will return to normal once the carb is fixed. You can look in the cylinder with a bore scope and see if the cylinder wall is scuffed.
Did you use OEM parts? You can do the fuel flow test in the service manual to check the pump. I would also check the pressure. Many aftermarket pumps have way too much pressure. Stock is about 1 or 2 psi.

What is the history of the bike? Has it sat not running for years? The carbs don't like that.

[Ffmedic166]

I think i figured out the issue. I will now for certain in the morning.

I was thinking about all that I have done and how it has air, fuel, and spark so it should stay running. I looked over all the work from the past couple of days and decided to look over the wiring diagram for the fuel pump since it was working then not and then was. I was probing the wrong damn wire. What i though was the signal/power wire was the reserve sensor. LOL So I find the correct wire which was the black/blue wire and had power....but here is where i think this was the issue. When I installed the new fuel pump one of the wires connector came off, yes that wire the black and blue, thinking nothing of it cause my previous bike had similar little box and was for the radio interference or whatever so i slapped a quick connect on it. Well it was not making a great connection and so maybe it was not priming the pump. SOooooo... I fixed the connection and rode around and so far its running good.

Ill ride in the morning the same route and see hows she does but i am sure she will run and not have any issues. Now i need to fix the the rich condition.

[Ffmedic166]

That is why I advised riding around with a fuel pressure gauge. Makes it pretty easy to troubleshoot fuel issues. I would say based on the plugs you have a problem with the left carb. Likely a stuck or leaking float valve. All that extra gas has washed the rings on that side and is probably responsible for the low compression. There is a good chance it will return to normal once the carb is fixed. You can look in the cylinder with a bore scope and see if the cylinder wall is scuffed.
Did you use OEM parts? You can do the fuel flow test in the service manual to check the pump. I would also check the pressure. Many aftermarket pumps have way too much pressure. Stock is about 1 or 2 psi.

What is the history of the bike? Has it sat not running for years? The carbs don't like that.

When my dad got the bike it had been sitting for years. The motor was filled with water. carbs were trashed and were junked out. and once we got the bike running it ran like **** for about two weeks of harsh and light riding around the block and streets. Was not registered at the time because the bike was rattling and ticking like crazy along with the oil light was on and we done about 10 oil changes with the month and worried about it not pumping oil. Then one day after basicly daring it to blow up and hot roding it. It slowly stopped rattling and oil like began to stay off. That was a year and half ago. The only issue and the reason the guy who had it previously stopped riding it was he was told the starter was shot. It was cranked when hydrolocked and stripped some teeth on the gear that spins when the starter spins over. its a bit noisy when cranking but she will crank and fire right up.

[johnnyco]

I had a GL1200 that would shut down in the heat. Just like hitting the kill switch. Found it was the pulse generators. They change their ohms rating when getting overheated and do not provide the proper voltage to the spark plugs. Change the pulse generators and your problem may be solved.

[77Goldwing]

Lots of things shut down in the TX heat.

In 1976 I was riding my 1973 CB450 to Guadalajara MX and had been riding alongside a stranger on his own bike from just south of Austin to a little north of Laredo. It was like riding through a sauna. As we approached a pullover he motioned to get off and we did to talk. It was just a dry, brutal heat by the side of the road. Fortunately a car was pulling out, then backed up and the lady passenger offered each of us a cold soda. Wow, did that taste good. And it did the trick. We rode together a few more miles before he headed west and I continued to Laredo for the night, before crossing the border the next morning.

[Wingsconsin]

Too Long Didn't read -- Admittedly I did not read all the answers -.

HOWEVER
I had a 1996 1500 and had similar problems -

FUEL PUMP is the answer --

The fuel tank gravity feeds until the tank is half gone - then the pump must work -
A weak pump gets weaker as it gets hot
Low fuel levels in extreme heat will cause fuel to boil (off) and cause a vapor lock of sorts
The FRESH fuel is cooool and the pump returns to normal plus the full tank gravity feeds again until half gone --

The test in the book says to pump fuel into a beaker - it does not say the beaker should be well ABOVE the level of the top of the tank

I can't exactly explain the poor fuel economy but the other symptoms I experienced 2X until I replaced the pump -

My bike 161,000 miles on it when I sold it but about 100K when the pump went bad IIFC .. ?

[Ffmedic166]

Too Long Didn't read -- Admittedly I did not read all the answers -.

HOWEVER
I had a 1996 1500 and had similar problems -

FUEL PUMP is the answer --

The fuel tank gravity feeds until the tank is half gone - then the pump must work -
A weak pump gets weaker as it gets hot
Low fuel levels in extreme heat will cause fuel to boil (off) and cause a vapor lock of sorts
The FRESH fuel is cooool and the pump returns to normal plus the full tank gravity feeds again until half gone --

The test in the book says to pump fuel into a beaker - it does not say the beaker should be well ABOVE the level of the top of the tank

I can't exactly explain the poor fuel economy but the other symptoms I experienced 2X until I replaced the pump -

My bike 161,000 miles on it when I sold it but about 100K when the pump went bad IIFC .. ?

She is running good and was able to try to go to Colorado lol. I made it from Dfw to Amarillo before my ass had to park it for weekend. The return trip back home lost air in front tire (valve stem snapped off while doing 80 mph). So I parked it again and today I went and picked her up and brought her home.

She has new fuel pump (aftermarket) and running good.

[Ffmedic166]

That is why I advised riding around with a fuel pressure gauge. Makes it pretty easy to troubleshoot fuel issues. I would say based on the plugs you have a problem with the left carb. Likely a stuck or leaking float valve. All that extra gas has washed the rings on that side and is probably responsible for the low compression. There is a good chance it will return to normal once the carb is fixed. You can look in the cylinder with a bore scope and see if the cylinder wall is scuffed.
Did you use OEM parts? You can do the fuel flow test in the service manual to check the pump. I would also check the pressure. Many aftermarket pumps have way too much pressure. Stock is about 1 or 2 psi.

What is the history of the bike? Has it sat not running for years? The carbs don't like that.

I got around to getting a scope down in the 4th cylinder….so black and nasty that the light was absorbed to point it’s hard to see. From what I guess is rust streaks and wet carbon all in this cylinder. The other cylinders you can see and make up the walls. Maybe this motor is trashed. Bike is down now for repairs and fitting a Weber carb on it.

What is your opinion? I have video and pictures.