Thank you for the responses... they really helped. I was able to properly set the timing. The bike over heated and fried the piston, it literally melted and popped a hole in the piston. The cylinder was surprisingly still in good shape and just needed some lite sanding. After replacing the piston, rings, pin, clips, gaskets, valves, flushing out the engine... I put it all back together and it cranked right up and ran for a bit until it over heated. So, I checked the waterpump and the impeller was free wheeling. I opened up the right crank cover and discovered the real reason the bike overheated and fried the piston. The circlip that holds the gear that connects to the small drive shaft for the waterpump and oilpump was gone...(huge design flaw in my opinion) so, no waterpump or oil pump. I replaced the circlip and put evrything back together and tried to start it and the starter motor fried. I have replaced the starter motor and all it does is grind a bit. Now I have a short somewhere that is keeping it fromk starting.
That's some impressive work.
Here is a general FYI on digital ignitions aka CDI for motorcycles and most cars:
Page 17-1 of the manual:
"The ignition system adopts CDI unit and the ignition timing cannot be adjusted."
The only "adjustment" for timing it to make sure the timing chain / cam gears, cam shafts are in the TDC position.
I'm not sure how the circlip came off but I've never had that problem on any scooter/ mc / atv and I have 23K on my 2005 Grandvista and I run it at 80-100% throttle on the highway most of the time.
Recommendations:
1. Don't use the starter until you crank the motor by hand by removing the cover and using a socket and ratchet. Depending on what you experience you might want to remove the valve cover and verify torque and timing of the motor - TDC mark.
2. Check valve clearance AND feel for resistance from compression. Too low compression = no start.
3. Remove the spark plug and crank the engine first by hand and then with the starter. When using the starter check for a visible and sound of a spark.
4. Report results to this thread.
Note: anytime the cooling system is disturbed or flushed remove the front plastic piece to directly access the radiator to remove the cap, expel trapped air and observe that there the coolant is circulating especially when the motor is revved. After the thermostat opens you can dip your finger or grab the hose to feel for warm / hot coolant. If you don't get that there is a problem: trapped air (most common), thermostat not opening, or in your case water pump is not spinning. Never flush the coolant and refill from the reservoir without accessing the radiator as that will result in trapped air and overheat the engine after about 10 minutes of idling /driving.
2.
