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Frank Angerano

My first Suzuki finally!!!!!!

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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. 

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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.

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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.   

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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 ? 
 

9386670F-5E82-46B3-B1A6-57B095CDE849.jpeg

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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

 

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Posted (edited)

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 by Frank Angerano

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

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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! 

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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.   

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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.  9804284E-0E83-4460-8716-604B28101088.thumb.jpeg.1df9cad43bd1aab4a8690798b630a0ea.jpeg

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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.

 

 

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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.

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

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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. 

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Posted (edited)

You have to have the barn set up before you get into all of that. Tools cleaned up etc, a work area and a beer fridge! 🍺

Edited by Frank Angerano

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Indeed and I've a wood stove to install. Yahoo!!!! We are starting to get an occasional warm day. I'm ready to get 4wheeling, cant convince the lawnmower to get the job done. Its stuck in a little bit of snow. Jeez

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RM Stator will rebuild/repair stators, too.  Good to know.

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Yes they do. I am impressed so far with the quality.  Flywheel puller showed up today so i might get onto it tonight, lets see. 
 

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Ok so new flywheel is in and she fired right up.  Huge difference, i can get to just about 80% throttle without any backfiring.
The carburetor is still in need of tweaking but i think the problem is solved. 

Unreal that something like this can happen.  What baffles me the most is the magnets on the old flywheel are solidly in place but yet they are incorrectly placed??? I tried to pry them off the flywheel with no luck.   So strange! 
 

Going to get after the carburetor tomorrow and take it for a spin before i put it all back together. 
 

Keep ya posted.....

 

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