2004 Boxer Cup Replica - Questions / problems

Discussion in 'Road Warriors' started by UT R1150R, Nov 14, 2017 at 12:15 PM.

  1. UT R1150R

    UT R1150R Long timer

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    I'm the very happy owner of a (new-to-me) 2004 Boxer Cup Replica but I have a few questions / issues to resolve so, thanks in advance for any advice :-)

    Some background...

    • Bike was in storage for about 2.5 months. I don't know how infrequently it was ridden before storage
    • Battery was dead after being in storage. Works well after charging.
    • 43,800 miles when I test rode it in California
    • 44,800 miles now after riding it back to Utah

    Issues / Questions

    • Headlight is useless. I rode across Death Valley at night and outran the headlight at anything above about 40 mph. Turning on the high-beam did nothing more than blind me with the blue high-beam light on the dash. I confirmed that the high-beam bulb works. I just expected it to outperform the regular light. Since this bike is unique I'd like to keep it stock, however I may have to put some Clearwater lights on it.
    • Engine idle is rough, is around 800 RPM and sometimes dies. This happens whether cold or after riding for a few hours,
    • Engine hesitates at about 5,000 RPM and continues to do so off and on approaching redline. This happens under gentle throttle and under hard acceleration. On the test ride, it was especially bad. Now that i have ridden it about 1,000 miles, run two bottles of injector cleaner through it, as well as ethanol-free fuel it is about 95% gone. Some research into this points to a variety of causes - bad stick coil(s), clogged injector(s), clogged fuel filter, split fuel line in tank, fouled plugs, improper seating of throttle cables in bowden box, issues with TPS sensor, issues with Hall Effect Sensor, questionable fuel-pump related relay connections.
    I would have already dug into all of this and hopefully be sharing wisdom instead of asking questions but I had rotator-cuff repair surgery 2 days after bringing the bike home.:cry

    Please let me know if I've missed anything or if you have other wisdom to share about headlights, engine performance, rotator cuffs, financial advice, the purpose of life, etc. i'll be down and out for 6-8 weeks :fall
    #1
  2. Zoef zoef

    Zoef zoef Been here awhile

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    Third bullet, would start with checking the stick coils, athough I`m not sure the R1100S has thrm.
    #2
  3. Achtung

    Achtung Wicked Pisssah Adventurer

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    Sync the throttle bodies, turn up the idle and replace the spark plugs (should be 4 of them). The dual spark four valve boxer motors are great, you should be good after that.
    #3
    JimVonBaden likes this.
  4. PaulBarton

    PaulBarton Adventurer

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    I would look into LED upgrade lights. I put them on my '01 GS with pleasing results. ADVmonster is what I chose (they are on this forum).
    #4
  5. UT R1150R

    UT R1150R Long timer

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    Thanks guys!
    #5
  6. maxjett

    maxjett Ride with Rocko

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    what Achtung said and also check the valves.
    #6
    Achtung likes this.
  7. M33

    M33 Adventurer

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    On the lighter side ... how did the rotator-cuff surgery go ... were you able to do arthroscopic or did they have to fillet you ?

    (I just had an MRI done yesterday and waiting to meet up with my surgeon to discuss the MRI findings next Monday)
    #7
  8. vagueout

    vagueout Long timer

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    Fuel filter replacement would be a good idea. Stick coils a serious suspect, if they are not starting to fail now they will in future, they have a finite life. I don't see any of this being related to the HES. Even more injector cleaner might help.:*sip*
    #8
  9. lewisjr1

    lewisjr1 Long timer

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    Gen. agree with the above suggestions. I'd start with replacing all fluids & filters. Plugs are easy enough, too. From their I'd ensure fuel hoses were both solid and flexible, without cracks or abrasions.

    Going into the tank is something I'd probably kick down the list until mechanicals were checked and, if nec., adjusted to spec. Of course, if you delve into the tank's internals, then try to do everything in one shot. And always be gentle with the tiny studs that secure the fuel plate.

    And the battery... If it sat for weeks in a dead state, it's highly suspect. IME, kinda like boobs, once they've gone flat they'll never be like new unless replaced.
    #9
  10. Norhasken

    Norhasken Tryin' to find my way

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    I had a BCP, even with a valve, sync and rocker arm adjust the windscreen would still shake at low idle, just the way the plastic is built. Battery is hard to get at, under the tank.

    Enjoy it, it is best at twice any posted speed limit sign.
    #10
  11. bykemike

    bykemike "ready to navigate"

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    There is a simple stick coil test so do that. I went all around on my stick coil issue with one of my GS's (04), even the BMW dealer didn't get it. Steptoe on this forum did though.

    BTW, I am a fan of the BCR, sold this to get the R1200S but this was a favorite of mine

    106_1364.JPG
    #11
  12. KMC1

    KMC1 There is no spoon.

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    It does sound like stick coils. There is a great article on here somewhere where the guy found some Ford stick coils that fit really well and saved a bunch of money compared to OEM. There was a lot of good info on symptoms and diagnosing the issue in that thread too. I don’t have time to search for it now, but totally worth looking into. :freaky
    #12
  13. bykemike

    bykemike "ready to navigate"

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    If it is an 04 it has stick coils, some symptoms: low power during acceleration, coming down from speed it idles roughly and may die, symptoms may not be as evident when the bike is cold, worsen when the bike warms up.

    Simple test: let the bike idle, is it smooth? Shut the bike down, pull one of the lower plug wires off and restart, smooth? If so shut the bike down and replace that lower and remove the other lower, smooth ? or does it not idle or idle roughly? The rough idle side may be your bad stick coil, switch the stick coils and repeat to verify if the problem follows that coil.

    If it appears to be a stick coil replace them both! I replaced one and was in the same boat 3 months later.

    (shutting the bike down in between messing with plugs minimizes the possibility of a surprisingly nasty shock, although you may be in a better mood for the rest of the day :>) )
    #13
  14. UT R1150R

    UT R1150R Long timer

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    this is great information. Thanks guys!
    #14
  15. UT R1150R

    UT R1150R Long timer

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    I discovered why the high-beam is totally useless. The bulb wasn't properly seated in the housing so it was resting on the reflective plastic and has melted a big hole in the housing. Now it points off at an angle. I'll try to find a used assembly (new ones are $800 :cry) since I doubt i'll be successful repairing it to the point where the bulb will be held in the correct orientation.

    Beemerboneyard has the housing for $285 but they are out of stock.
    #15
  16. KMC1

    KMC1 There is no spoon.

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    This is the one I was thinking of:

    http://advrider.com/index.php?threads/coil-sticks-no-more.713106/
    #16
  17. JimVonBaden

    JimVonBaden "Cool" Aid!

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    Before replacing parts, do a general service on it. Adjust the valves, clean the BBSs, adjust the idle to 1100+-50, and change the plugs. Likely that will fix it. I don't even think stick coils until ll that is done. At $165 each, that is pricey if you have not removed other issues.

    For the light, go HID or LED. Big difference.
    #17
  18. UT R1150R

    UT R1150R Long timer

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    I started taking her apart today to get ready for a full tune up.

    The top plugs looked perfect (tan, dry and very little deposition).

    The bottom plugs were mostly black, had lots of carbon deposition, were slightly wet and smelled like gasoline. How is it possible to have such a different outcome on plugs from the same cylinder? Any tips on what the cause would be?

    I plan on replacing the plugs, fuel filter, air filter and stick coils so that may take care of it but I hope I can know the cause for sure so I can prevent recurrence.
    #18
  19. JimVonBaden

    JimVonBaden "Cool" Aid!

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    This is pretty common. The lower plugs will almost always be slightly sooty. It is not an indication of an issue.
    #19
  20. UT R1150R

    UT R1150R Long timer

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    Excellent. Thank you
    #20