Hey Phil,
Sorry to hear about your foibles at Bandy.
Re: the throttle return. First check to see if there are any kinks in the
cables. Then make sure all the return springs are properly installed. The
shop manual has a section (don't know pages offhand, but you can check the
carb section of the manual for info) that describes the linkages at both
ends.) My guess is either a kink or a return spring problem, though.
Re: The kill switch/charging problem(s). I'm still stumped about the kill
switch delay. When you showed it to me at the track it struck me as strange,
and still does. But you may be on the right track with the ground idea. Try
taking off the main engine ground strap, that's back by the oil fill. Sand
or wire brush the case and the connector and the bolt face then reinstall.
It's possible that there's a ground problem that is intermittent due to bad
continuity. Maybe when PCW painted the case they didn't clean the
connection. I recently did the same procedure on my max and found that the
whole area on the case was black, with only part of the case making
connection, and not a great one at that. I wire brushed the area and my
charging system is working much better now. It came that way from the
factory, but was just marginal enough to work, sort of.
Could it screw up the ignition? Possibly. You might also sand or brush the
ground connection to the frame, just above the battery ground connection.
Re: the pilot circuits, and could they affect the main mixture. Yes. It's an
additive system. The pilots are always feeding fuel, and they're added to
what the mains feed, so if you're (severely) too lean with the pilots and
just right with the mains, you'll be too lean at open throttle. If you're
too rich with the mains it'll make less of a difference.
Good luck,
Sat Tara
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