My first Suzuki finally!!!!!!

[Frank Angerano]

Checking stator to see if the coils are good.  
Yes, pulse/trigger coil testing to see if within range.  
Yes oil needs to be drained.   

[Jim Denton]

Haven't been here for a while and just knew I was going to see the solution. You've got the big daddy of gremlins there Frank. You're not going to like me anymore but I think something might be plugged up in the high speed circuit in the carbulator. If no joy from the electrical components you're waiting to swap pull it again. Dang I feel your pain. 

[Frank Angerano]

Ok so update, finally got a little time to play in the shop.  Swapped out the regulator and guess what?????? NO CHANGE! FML.... 

Decided to pull the side cover off and pull the stator and flywheel off. Stay tuned.......

IMG_3837.MOV

[Frank Angerano]

Need the video converted. Maybe @Ajmboy or @Admin can help me out.  

[Admin]

2 hours ago, Frank Angerano said:

Need the video converted. Maybe @Ajmboy or @Admin can help me out.  

Thanks for tagging me @Frank Angerano, that's what brought me to this topic 😉

The issue is that iphones save videos as .MOV, and android, windows, and browsers like chrome do not automatically play .MOV files like MP4 files. Its usually the browser. .MOV is a quicktime file and will play in iphones and in safari browsers. 

I've converted it to .mp4

[MarkinAR]

@Frank AngeranoThat sounds like a rev limiter so I'm betting you're on the right track with it being electrical. Cranky plug, internally broken wire somewhere....something along those lines I bet. 

[Frank Angerano]

@Admin thanks! 

@MarkinAR i have a new oem harness on the atv and all wiring is solid from top to bottom. I have not found a rev limiter on this machine so far but definitely a good guess.

Heres where I'm at;
I checked the flywheel and all magnets are solidly in place and have plenty of magnetic power.  I have seen where magnets will slide along the inside of the flywheel due to the epoxy holding them in place failing. No such luck, i did however find a spliced wire coming off the stator coil so I'm not taking a chance since i have it all apart im going to throw a new stator and pick up coil in.  

After that the only thing left is the cdi!  I put another one in (aftermarket) but it ran the same.

This ones a toughy !!! Going to get it straight though.  
 

[06kfx440]

I’m following this. I’m pretty stumped myself.


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[MarkinAR]

@Frank Angerano, it seems you have addressed everything on the pre-combustion and combustion side...what about exhaust.  Any chance the something from the header back to the muffler limiting gasses escaping?  Maybe it can't move enough gas out to rev?  Muffler partially clogged?

[Dra O]

great stator pics, frank - will help me in the future on the honda.  i'd seen youtube video on magnets coming off, too.  that thing sounds ROUGH, man.  you'll get there

[Frank Angerano]

@markinar i have no idea about anything possibly in the exhaust and its a great point. I will pull the exhaust pipe as soon as i get in and get back to. Good point though.  
Stator/pick up should be here tomorrow. 

@Dra O thanks buddy, wish i was posting them under different circumstances but the mystery continues! Maybe saga is a better choice of words lol 

Thank god for 🍺 

[quadnut20]

Darn no luck yet ?? Following !!

[Frank Angerano]

@quadnut20 yes sir, still on it!! Haven't had a lot of time due work so i get an hour or two here and there  but yes its a pain in the as* for sure, however this atv is like a good book that will have a crazy ending. 
I ordered a few parts and that will rule out any internal problems. The flywheel magnets are good and have plenty of power so I'm assuming the flywheel is good.   
 

Hoping its the pick up coil and we will be good.

I have about 15 hours of time documented so far. 

Keep you posted. 
 

[Frank Angerano]

Been doing a lot of research on this flywheel and although its seems ok there have been issues!  Since i have it open im thinking of just throwing in a new RM flywheel! 
 

Thoughts ??? 

[MarkinAR]

You and I both hate throwing parts at it without knowing they actually need replacing...and flywheels aren't exceptionally cheap.  But I'm not sure what's left, you've pretty much ruled everything out.  Listening to the video, I'm not hearing a fuel issue, I'm hearing something electrical intermittently cutting off under load.  Under load issues are nearly always heat or gravity related so if it does it with a cold motor that almost only leaves gravity.

[Frank Angerano]

So a flywheel it is then! 
Found a deal on an RM stator flywheel for $123 new.  I have the new stator at the garage. 
Going to pull the trigger today for the flywheel. 

[MarkinAR]

I bet that's it.  Thinking back, this was an electrical fire at some point so if you replaced the harness and the usual plug, plug wire, coil, etc test good then you've resolved about every end point on the harness that has an effect on performance...so it almost has to be the flywheel and/or stator.  I assume you ohmed out the reg/rect and it's good.  I'm firmly convinced this is electrical related.

[Frank Angerano]

Yes sir @MarkinAR i have done everything you mentioned including ohming the stator and pick up coil.  All within spec, i was hoping that i would get a bad pickup coil but nope.   So anyway i will change the flywheel since its open and put all that to rest.   

[Frank Angerano]

Ok so i have the new stator in hand and the flywheel is in transit. 
Heres my question! Ive researched OEM images of the flywheel and none of them show me the multiple gaps in the magnets like i have. 
Maybe im crazy but take a look at this and let me know what your input is.  I may be wrong but I haven't found any OEM flywheels that show the breaks in the magnets except for the one gap that triggers the coil.   
 

Thoughts ? 
 

[Dra O]

measuring from a computer picture not very accurate, but it looks like if you got rid of the gaps you'd have room for one more magnet

video from an arctic cat 400 but may help - start at 2:00 - your issue may be at 3:00 but i'm pretty confident you've already done this

 

[Frank Angerano]

Thank you @Dra O and yes i have done this. Either way I'm swapping the flywheel and going to close that end out.  Hoping i fire it up and we are good. Keep you posted. 

 

Edited March 1, 2020 by Frank Angerano

[Jim Denton]

Wow looks like the Dr. nailed it Frank. Makes those gaps pretty suspicious. 

[Frank Angerano]

I agree and think this may be the problem. 
All i need now is the flywheel.  Should have it in my possession by Wednesday.   
Keep ya posted! 

[Frank Angerano]

Popped in the new stator since i had a little time today and stripped the old gasket remnants off (that never gets old) lol.
 

So i decided to do a thorough inspection on the old one. I pulled the plastic sleeve off of the wires because i felt a lump inside the sleeve and..... someone was in there! Wires were taped under the sleeve and found three but splices.
 I also found a part of the insulation that was damaged where the retainer strap holds the stator wires in place in the cover.  
Whoever spliced the wires put a vinyl sleeve over them and it almost looked factory.  
Anyway new stator is all good and the cover is clean and ready for reinstall.  
Waiting for parts is the worst! 
Check the pics.   

[Frank Angerano]

Ok so parts are finally in my possession, stator is installed. Flywheel is here but of course my puller broke!!!!! Wtf???? New one is on the way.   
 

I like this new flywheel, looks and feels well built.  

[northernmi]

Interesting flywheel, it has solid magnet ring pressed into it, no magnet gaps. 

If this is case, along with what you discovered with stator, that would influence ignition timing @ mid to top end due to 2 magnet gaps? 

Since there is no physical damage to the old stator frame or mounting area. Guess that rules out a magnet breaking inside, and then WHO ever? re-appoxing the 2 exisiting magnets creating a gap. My guess, incorrect flywheel was installed @ factory or by former owner.

 

 

[Frank Angerano]

@northernmi i agree. Going back together on Sunday.  I will keep all posted.   

[Jim Denton]

Or possibly a stamped ring epoxied in? Much better design whichever. Frank where did you source this if you don't mind my asking? With the milage on my pile I may need one.

[Frank Angerano]

RM stators.  They have flywheels and stator coils.  Waiting on my new puller for the flywheel. Should be here today.  

[Jim Denton]

Thanks for the info. I saw that you had mentioned them but my old man brain thought you were going to repurpose a dirt bike part somehow. I can't wait to start on my pile but have been trying to get a barn turned into an actual workshop.