[RevLee]

Noticed that over the past year it was getting harder to start the bike. Rebuilt the carbs about a month ago and she ran fine, but if the bike sat more than a couple of days it was very stubborn to start, but ran fine once I got it started. I ran it 4 hours a couple of weeks ago with no problems, but last weekend couldn't get it to fire. Tried last night to start it and gave up after 30 minutes. Thinking I have an electrical issue I checked my plug caps today. One resister end fell apart, and there was a little corrosion on both. The one which was intact read about 2.5K. Put it back together and barely got it to read. OK, so I know I neede to replace the resistors. Heading out to look for a brass rod to replace everything in the cap. While I had things apart I went to check the continuity of the CDI/Stator using this method, My link



OK, fine so far. The problem is that every reading shows a short! By the way, I verified my meter is ok and my connections were sound (I have worked in Electronics for many years so I know what to look for with testing hookups). Now the only thing was that I had both Plug caps off the bike when I first tested it, but I reconnected one and still saw the same short across every circuit. Any ideas??

 

[RevLee]

Status update. Was not able to find a brass/aluminum rod locally so that will have to wait until next week when I get down to Raleigh. Put the Plug caps back together and was able to get her to fire up (struggled a bit to fire, but eventually she did). Now she will fire right up again. Obviously I am chasing a intermittent problem here. Is there any good way to check out the Stator? Tried checking some voltages when cranking it on the white and blue wires with a 0 volt reading. Also tried unplugging the 3 yellow wire connector and she still fires up.



I know the plug cap issue might be the culprit, but I don't think that is my only issue.

 

[Blindstitch]

Brazing rod will work and the other options should be available at many major chain hardware stores.

 

[Reg in Bristol]

I'm a bit puzzled here

I think its clear you need to mod, or get new, non resistor plug caps

and you have an intermittent fault too



I'm Ok up to there but

the stator readings of all shorts and no voltage output on the blue and white wires

yet the bike runs, doesnt sound right at all.



Perhaps your meter is faulty or needs a new battery?



If you really had a short between every pin and ground on the stator connector you'd

get nothing out of the bike.



Experience tells us the most common fault is the CDI charging coils failing

If so, you'd expect see in spec readings on eveything except white to ground

and/or white to blue.

 

[RevLee]

I'm a bit puzzled here

I think its clear you need to mod, or get new, non resistor plug caps

and you have an intermittent fault too



I'm Ok up to there but

the stator readings of all shorts and no voltage output on the blue and white wires

yet the bike runs, doesnt sound right at all.



Perhaps your meter is faulty or needs a new battery?



If you really had a short between every pin and ground on the stator connector you'd

get nothing out of the bike.



Experience tells us the most common fault is the CDI charging coils failing

If so, you'd expect see in spec readings on eveything except white to ground

and/or white to blue.

I plan to grab some brass rod on Thursday when I make it down to Raleigh where there is a Grainger store. I live out in the sticks so supplies can at times be limited.



As for the meter, I have tested it to make sure it's working (first thing I did) and it's fine on both voltage and resistance testing on other areas (off bike). I agree with the intermittent issue, it's driving me nuts. I need to retest the resistance now that the bike decided to start to see if anything changed. This is the reasoning behind my post to see if I am missing something. Obviously something is amiss with the test as the bike would not run if they were correct.

 

[drummertom]

I plan to grab some brass rod on Thursday when I make it down to Raleigh where there is a Grainger store. I live out in the sticks so supplies can at times be limited.



As for the meter, I have tested it to make sure it's working (first thing I did) and it's fine on both voltage and resistance testing on other areas (off bike). I agree with the intermittent issue, it's driving me nuts. I need to retest the resistance now that the bike decided to start to see if anything changed. This is the reasoning behind my post to see if I am missing something. Obviously something is amiss with the test as the bike would not run if they were correct.

GROUNDS GROUNDS GROUNDS!! I am becoming more convinved that a lot of problems on these bikes come from bad grounds. My temp guage wouldn't work, turned out to be a bad ground, It quit firing on one cylinder, I switched coils from one side to the other, and it got better, but not well. I made ground wires and made sure both coils were grounded good and it ran/runs like a top now. OBTW, Where is Nathalie?

 

[RevLee]

Probably need to do a good once over on the wiring, and yes, need to redo all the grounds, sure won't hurt.



Nathalie, VA is about 20 miles NE of South Boston, VA and about 1 hour south of Lynchburg.