I've got an issue, one of many when it comes to bikes. I searched throughout all the pages I could find pertaining to my situation and couldn't find very much useful information.
So the issue is, the bike has no electric start.... until it's hot enough to melt steel that is. It will bump start first time every time. But I can sit and crank the starter over for ever and it'll never start until the charger is bumped up past 200 amps. Not good.
The story so far,
Got the bike for 1k cash. Guy said it has no spark and no second gear. This particular guy also only ever rode newer crotch rockets. Brought it home pulled the choke, attached battery charger and she fired right up. Ran like absolute crap, but oh well I figure it's an older bike with only 10k miles so it probably needs a good carb cleaning. Took the carb apart and didn't know I messed something up until way later(didn't tighten down main jet). Oh well she runs well enough if I can get her started. Moved from California to Oklahoma. Eventually found the money to fix 2nd gear, and as I am a certified Honda small engine technician apprentice I figured it would be no big deal. Completely tore down engine to it's roots replaced 2nd, and 5th gear(because 5th gear connects to 2nd on the countershaft) dogs were worn pretty badly on both. The engine looked quite good compared to most others I've seen. Put the engine back together as per the service manual. Did all the right steps including loosening the banjo bolts to test for proper oil pressure. I even tore apart the electric starter to clean the contacts and the brushes and replace the dielectric grease. Adjusted the valves as per the service manual, replaced all gaskets, o-rings, seals, and oil filter.
Finally after about a month of waiting on parts and reassembly I get to start her, only she doesn't. Electric start is still giving me the same issues I've always had. So I replaced the Ignition coil, CDI box, and put a new battery in, plus the starter motor rebuild. Nothing. Still cranks forever. I said what the heck and tried to push it slightly down hill and bump start it, and voila... fired right up! Once she gets hot enough and the stator charges the battery enough it'll electric start... sometimes.
So I looked towards ignition, used a tool called ignition mate. Pretty awesome tool if you can afford it. Well while cranking the ignition mate reads the spark plug is getting 1-4kw of "spark" every cycle, well it only fires after getting up past 5kw sometimes 6-8kw. And sometimes the ignition would be intermittent as in it wouldn't give any spark at all. I cycle the ignition and it seems to soft reset the bike as it will usually give it back spark. I tested this with the new and old CDI box, the old one would never spark. Ever. So I threw it in the trash. A month later I stil l can't figure it out.
Is there something I'm missing?
Bike won't start using electric start only bump start before and after engine rebuild
Electric start works after pushing the starter past about 200 cold cranking amps or when hot.