Leaderboard

First check the wiring for breaks in the wiring from the stator to the main wiring harness. Next use a multimeter to chech the resistance between the yellow wires coming from the stator. From one wire to the next it should have less than 2 ohms. A high or infinite resistance between two of the wires indicates an open in the stator wiring which is fixed by replacing the stator.

Topic moved to Suzuki forum. @Marcus, I removed your three other topics on this same subject. You do not need to post in multiple forums, try to keep it to one topic per theme/issue. Thanks.

Update: Well I finally got a chance to let it warm up and test the stater and other winding's to make sure they are not breaking down when hot. The readings were within tolerances so I moved on to checking the valves. I decided that this engine has some miles on it so I changed out the valves, springs, and cam. Started right up and again at 1/3rd throttle she would start to sputter and die. So I am really frustrated with this machine. Everything tells me its electrical. So I needed to walk away. So this morning I went out and worked on it and tried to approach it like it was the first time it messed up. i started the machine and checked voltage at the battery. 12.2 static and when started 14.2. No problem there. So I thought I never checked that voltage with the machine above idle. So i got some clips and left the meter attached. At about 1/3 rd throttle I am pushing 16 volts if i push it or rev it I can get the voltage to go clear up to 19, 20 volts at the battery. So the rectifier is bad because the voltage at the battery should never get about 14.5, which in turn most likely f,d the CDI. I am going to do some more checks and will post. Hopefully this is it. This machine will have almost all new parts. I probably should have pulled the jug and got new rings and piston while I was at it. Thanks for the inputs and if anyone has any other suggestions please let me know. Thanks and I will try to ensure I post once i get the new CDI, Voltage Regulator and rev limiter. To day I am going over all the wiring and checking and cleaning all the terminals to ensure there are no other electrical issues

I added to your topic title a bit so maybe you'll get some answers. 😀