symptoms before non-starting problem:
1) higher speed/rpm miss in 4th or 5th gear, around 50mph. i do not have a tach.
came home, from ride last sunday (oct 9th 2011) and dumped the float bowl to check for water in gas. none. checked for dirty filter, it wasn't. tried to start, no joy.
bought with 8,000 miles, immediately realized the stator was not charging. replaced with new rickystator. ran fine until 1 1/2 months ago, began non-charging condition again. replaced with free-replacement from rickystator.
all electric connections have been cleaned, lubed, and reconnected.
battery replaced 1 1/2 months ago, no starting issues until this problem
battery shows 12.9V key off
battery shows 12.9V key on (give or take very little)
battery shows 12.64V key on starting
battery recovers quickly to 12.9V after starting attempt
stator charged @ 13.5-14V (LAST TIME IT RAN)
stator test of three yellow leads = good stator
stator test of output not possible (non running bike)
free power mod done
coil tests (cold) 15K ohm
spark plugs are new, gapped .031" ngk cr8e
spark is fat and blue, will bridge .400" gap from screwdriver to ground. or a finger, and that hurts, twice.
spark plug is wet after several attempts at starting
intake and exhaust valves within spec, iirc .004" IN and .008-.009" EX
cams appear timed correctly, chain is snug and quiet
TDC mark on flywheel appears to coincide with cam timing
manual cam chain tensioner installed 2 weeks ago
oil changed at or before 1,000 miles, suzuki filter, 20w50 castrol non-synthetic for summer
normal starting (cold) procedure:
full choke, blip the starter and she lives. drop to 1/2 choke in 20-30 seconds, idle 2-3 minutes, then ride. great performance from idle to redline, but i rarely rev it that high.
bike has been completely reliable other than stator issues in the past, and crappy gas.
I don't know how to disable the auto-decompress, and my compression gauge won't fit in the plug hole for the frame's interference. (no compression test other than thumb on the hole)
bike does not backfire, pop, or sound like any explosion is happening at all when attempting to start. will not start with ether.
I guess this is where I ask for help again ?
Edited by ohgood, 14 October 2011 - 09:03 AM.