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Valve shim size

Your bike doesnt have points and condensers. Its honestly going to be hard to diagnose without seeing what its doing in person. But the main issues with these bikes are the valve clearances going tight, the never ending carb issues, coils and the little ignition boxes. Its also common to have the timing chain tensioners fail which can cause bad noise but can simply may need to be adjusted.
Hey, Dirtdigger.
I do know about carb nightmares, had a fair share. Lol.

I tested my ignition coils this morning.
Coil for 1&4: Primary 2.5ohms
Secondary (cap to cap) 22.5k
Coil for 3&4: primary 2.7ohms
Secondary (cap to cap) nothing
The bike does run on all cylinders so I need to measure those coils again once the bike is warmed up.
Tried to upload a short video of what it is doing but the 15 second file was too big
 
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If your coils stop working when hot, they will do that at any rpm not only 6k and up!

I think you have issue with carbs, when I took my carbs apart there was crazy amount of some fine grit inside vacuum piston bores and throttle was sluggish to say at least.
During carb cleaning, I used aluminum polish and hand polished bores and pistons, float bowl check valve seat…
I can with good amount of confidence say that is reason besides clean and balanced carbs for my throttle and engine smooth and rev happy operation.
 
If your coils stop working when hot, they will do that at any rpm not only 6k and up!

I think you have issue with carbs, when I took my carbs apart there was crazy amount of some fine grit inside vacuum piston bores and throttle was sluggish to say at least.
During carb cleaning, I used aluminum polish and hand polished bores and pistons, float bowl check valve seat…
I can with good amount of confidence say that is reason besides clean and balanced carbs for my throttle and engine smooth and rev happy operation.
It isn't clear to me that coils ALWAYS fail at any rpm when they go bad. I've seen multiple sources claim hot temperatures can affect spark delivery when the coil deteriorates. However, you're right, when they absolutely fail, they do fail absolutely.
 
It isn't clear to me that coils ALWAYS fail at any rpm when they go bad. I've seen multiple sources claim hot temperatures can affect spark delivery when the coil deteriorates. However, you're right, when they absolutely fail, they do fail absolutely.
As an example of how coils can degrade: on one of my other machines, a 1997 BMW R850R, the coil is basically a square plastic cup that houses the circuitry and the manufacturer poured red epoxy into the cup to seal things off. Over time and heat cycles, the plastic outer shell will expand away from the red epoxy center, allowing air and moisture to leak in and corrode the electrics inside. That bike would, at a hot idle, stumble every few seconds, but on throttle it always ran great at any RPM. This was just the beginning stage of what would eventually (probably years later) have been a complete failure. I replaced that coil and the idle is now very smooth.

Brett, I think you have a carb issue. At least one of the four slides isn't rising or at least one of the carbs is not getting enough fuel through a clogged main jet at higher RPM's. I can't think of a single thing in the cylinders or valvetrain or even the spark system that would prevent the bike from revving out past 6k. None of those things are RPM-dependent on this machine.
Unfortunately your issue is combined with known-low compression, so you have a choice to make. You can remove only the carbs and figure out what's going on inside them, or you can pull both the carbs and the engine out and do the top-end work. Up to you. With low compression and properly functioning carbs, you could simply keep riding until the bike is so slow you can't stand it and then yank it open to do new rings.
I tested my ignition coils this morning.
Coil for 1&4: Primary 2.5ohms
Secondary (cap to cap) 22.5k
Coil for 3&4: primary 2.7ohms
Secondary (cap to cap) nothing
The bike does run on all cylinders so I need to measure those coils again once the bike is warmed up.
Tried to upload a short video of what it is doing but the 15 second file was too big
If you measured the coil between 3 and 4 then of course you'd get no ohm reading as those two aren't connected. Make sure to measure between 2 and 3 and don't be afraid to push the multimeter probes in there a little harder to get past the rubber end. You should see a brass terminal inside the spark plug boot and that's what you need to touch.

I feel like a freak when reading internet motorcycle forums -- I have not once had a serious it-won't-start-or-ride carburetor issue on any of my multiple carbureted motorcycles since I started riding 6 years ago. On every bike that's new to me I either rebuild the carbs myself or have receipts on hand to prove a professional did it. Then, I do two important things: one, I always treat the gas in the occasional-use machines with Sta-Bil; and two, I refuse to let them sit for long periods of time. You will never have "endless carb nightmares" if you ride the damn thing at least once a week or two, are mindful what kind of fuel you're putting in, and do the prudent things before storage (draining the carb bowls!).
The only issue I ever had was starting my GS500E after it sat for 9 weeks because I broke my ankle crashing it. It had ethanol gas in it too. It started, but it didn't run very well. I threw some Seafoam in the tank and limped it around on a ride and it got better and better as the miles ticked by, until about 100 miles in it was running perfect again.
Nowadays I'm spoiled by my fuel-injected BMW's but the vintage 4-carb Honda is still around and still running strong. Learning how to fix fuel injection was a whole ordeal in itself, but that's a story for another time...suffice to say I prefer carburetors even now that I've owned two fuel-injected bikes.
 
I hear you on the carbs, Sense. I will look at those again before I decide to go further into the rings scenario. And thanks for the reply, that must have taken some time.
I messed with the spark plug wires today (yes, I meant coil 2 was for cylinders 2&3).
I could NOT get a resistance reading between those plug caps. Took both caps off and both wires from the coil. Found corrosion in the wires, enough to prevent me from getting a reading. After cleaning (and some trimming of) the wire ends I could get a good reading (25k ohms).
Valve shims come in today. So far clearances look good except for 4 or 5 of them.
I will ride the bike after this valve job and see how the revs go and how the idle performs. If I have either issue after the ride I will break open the carbs again.
Appreciate the help!
 
I could NOT get a resistance reading between those plug caps. Took both caps off and both wires from the coil. Found corrosion in the wires, enough to prevent me from getting a reading. After cleaning (and some trimming of) the wire ends I could get a good reading (25k ohms).
Hey, that's a definitive problem. I'd replace all four spark plug wires since you know at least two were corroded -- bring one wire to your local auto parts store so they can measure the width and they'll sell you a new length of wire for a few bucks a foot. Easy way to reduce future headache and I think you only need 8 feet at the most.

Also, there's an easy solution here you're overlooking -- you could just ride the bike under 6k rpm all the time:smoke:
 
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Hey, that's a definitive problem. I'd replace all four spark plug wires since you know at least two were corroded -- bring one wire to your local auto parts store so they can measure the width and they'll sell you a new length of wire for a few bucks a foot. Easy way to reduce future headache and I think you only need 8 feet at the most.

Also, there's an easy solution here you're overlooking -- you could just ride the bike under 6k rpm all the time:smoke:
Yeah, I thought about getting new wires. For 70 bucks, from 4-into-1, I can get two coils, four wires, and four caps. not sure how old all of those things are on the bike so I could replace it all for not too much.
And you know what, I have absolutely thought about riding up to 6k indefinitely. Lol. Definitely would be willing to do that for a while until I really needed to get into the rings.
 
Here are the indicator lines on the exhaust cam. As you can see, there are 2.
20230807_132725.jpg
 
Save your money. If your coils are OEM and in good shape without any cracks or warping of the plastic cases and the resistance tests right, there is no need to replace them. The OEM coils are great quality and a lot better made than most aftermarket ones.
You can test the spark plug caps for resistance -- should be near-zero unless they're resistor caps in which case they'd be about 5k ohms. You don't need resistor caps on this bike, so if they do test that high I'd replace them with non-resistor caps to get hotter spark.
Wires shouldn't cost you more than $30 at the local store. If you want to be precise you can measure the exact length of all four of your wires and buy only that. I think my local O'Parts charges $2.50 a foot for black spark plug wire.

Thankfully your pic makes it easy. The slot marked with paint from the factory, the one on the right in your image, is the marking the manual refers to. I figured this out with my own machine's camshaft replacement and wrote it down. Only the paint-marked slot will, when placed horizontal, make the cylinder 4 camshaft lobes point away from the spark plug like the manual says.
 
Save your money. If your coils are OEM and in good shape without any cracks or warping of the plastic cases and the resistance tests right, there is no need to replace them. The OEM coils are great quality and a lot better made than most aftermarket ones.
You can test the spark plug caps for resistance -- should be near-zero unless they're resistor caps in which case they'd be about 5k ohms. You don't need resistor caps on this bike, so if they do test that high I'd replace them with non-resistor caps to get hotter spark.
Wires shouldn't cost you more than $30 at the local store. If you want to be precise you can measure the exact length of all four of your wires and buy only that. I think my local O'Parts charges $2.50 a foot for black spark plug wire.

Thankfully your pic makes it easy. The slot marked with paint from the factory, the one on the right in your image, is the marking the manual refers to. I figured this out with my own machine's camshaft replacement and wrote it down. Only the paint-marked slot will, when placed horizontal, make the cylinder 4 camshaft lobes point away from the spark plug like the manual says.
Caps were very easily measured at 5k ohms.

I did figure out the painted mark was the right one when I rotated the engine to use the other and cylinder 1's exhaust valves were pressed into the shims (which are the ones you are supposed to measure).

I appreciate the advice on the coils. I'll use the cables and grab some from the auto parts store.
 
Did the valve shims, cleaned and trimmed spark plug wires and caps, opened the timing cover. Timing was a little off so I fixed that. Some oil, a tablespoon or so, came out of the timing cover. Is this normal?
 
Ok, valve shims and/or timing were the fix for revving through the entire range. Just got back from a 10 minute ride and she was awesome.
Now I'm letting her idle to see what she does. This stuttering at idle sounds like a misfire to me. It picks right back up after the stumble and the stumble lasts half a second. I have my spark plug light tester to put in-between the spark plug and cap to watch the lights. I'll do this once it dies.
1 problem down, 1 to go.
THANK YOU for all those that were bearing with me.
 
Quick follow up, it sputtered a bit but never died. I'll ride for longer one day this week.
My coils tested good (25k ohms each). What is in the same circuit as the coils that I can check?
 
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