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Need some brainstorming

  • Thread starter Thread starter kungpaodog
  • Start date Start date
If the plugs are a light brown on the ceramic around the center electrode, that's generally a good sign that the jetting is good and the spark is adequate. You can still have an intermittent problem that would likely be a poor electrical connection. Higher rpm's usually helps a poor connection, at least it seems to perform better.
I tend to think it's electrical. Specifically, a poor connection.
 
Thanks Chef, Keith, Chip, Dick.
I took a few days away from the bike to go snowboarding, so here I am again, still looking for new ways to confuse myself...

I chopped about .25" off of the plug leads and put the caps back, on, and the plug caps look to be in great shape. There was just a little bit of corrosion on the wire ends, but not enough to get me worried.

The voltage at the orange wires going into the coils was 11.5 on one side, and 9.5 on the other (the 1/3 coil). Then I disconnected what I'm pretty sure is the R/R connector and the voltage went up to 11.5 on the 1/3 coil. Is this right?

Then I put a timing light on her, and while the advance works perfectly, the 1/3 coil seems to be very intermitent at higher (over 4000) rpms. The 2/4 coil seems to work well at most rpms, at least my timing light fires a lot more off of the 2/4 coil than it does the 1/3 coil.

To top off the confusion I checked the voltage again after I did the timing check, and voltage was 11.5 at the positive leads going in to both coils.

Do I need to tear into my wiring and/or do a relay bypass to the coils? The wiring looks very clean all around.

Do I need a new R/R or do I need new coils? I'm leaning towards new coils, but wanted to ask first. And I also wanted to know where I should order them from. Plug your buddies business here!

Thanks for all the help guys, I know this is a lot of info to sift through.
 
Just to avoid troubleshooting confusion, one coil fires 1/4 and the other 2/3.
The voltage to your coils should be higher. Clean connections everywhere are a must, as is a correctly charged battery.
Check the coils secondary (plug cap to plug cap) resistance. Generally, 31 to 33 ohms resistance is good, but I'm not sure about your specific model. Check the primary resistance, it should be between 3 and 5 ohms.
Your ignitor controls power to the coils. It could be failing, but I'm hesitant to advise about testing it because I don't consider myself experienced enough with them. You can short out/damage things if you test them incorrectly. The only info I have about testing the ignitor is when using a specific Suzuki tester. I can post that info if you want it, but I don't know how the use of a different tester you may have changes the procedure.
You said your signal generator passed its test.
Your test light showing intermittent spark at one coil certainly suggests a problem.
Coils generally fail more often than ignitors. Unless you can make thorough tests of the ignitor, I'd probably look at replacing the coil that was part of the intermittent sparking. Of course, I'd make sure that each and every connection is solid/clean first.
 
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