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Dead flywheel?

R

Robzerg

Joined Mar 2019
10 Posts | 1+
swiss
Hi everyone,

I'm having an ignition problem on my 2003 fs650.

The stator is new and is an electrex ST5410L model (I also tried with two other original stators). I don't use the regulator/regressor part because I use the bike only for the track and I don't have a starter and lights anymore.

-The stator resistance is within the range indicated in the workshop manual.

-The resistance of the secondary winding of the ignition coil is about 3.8K ohm and about 1.7 ohm for the primary.

-The spark plug cap resistance is 4.9K ohm.

- The wire harness is correctly connected, and I've also tried disconnecting the orange wire from the killswitch.

What worries me is that the A/C voltage at the stator output is very low. With a good kick it's hard to get more than 3V between the green and red wire (without a peak voltage adapter). So I'm wondering if my rotor (SEM) could be faulty.

Probably the voltage should be closer to 30-35V, but a faulty rotor seems rather unlikely.

Does anyone have the possibility to measure the stator output voltage to compare?

Thanks a lot
 
Hello !
Sorry i forgot to explain that..

There is no spark at all ... And back in the time the spark was very low
 
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Most likely your ignition module/box is destroyed.
That's the second guess in those years.
Unfortunately they can't be measured.
I have new modules ready. Maybe worth a shot... Where are you from?
 
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Thank you for your reply ! I'm from Geneva in Switzerland.

Are you talking about the ignition coil? I'm not sure about that either. What models do you have?

I'm also worried about the stator output voltage, which I find really low.
 
If it's not the ignition module, I'd check the magnetism of the flywheel. I had one that lost sufficient magnetism that the spark became too weak to drive the motor. I remember going through the whole electrical system looking for a bad ground, broke wire, whatever and it came down to the flywheel. It's not often that such a thing happens, but I can say from experience, it does happen. Replaced the flywheel and all was good.
 
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That's my doubt, do you think there's a way to diagnose a rotor that no longer works?
 
Hello Robzerg,

I'm having the exact same issue. Same model bike. Except in Australia, went from bike running to weak spark then no spark.
I have brought all new components (coil, stator, CDI) checked all wiring 100 times over.
Now looking at flywheel
Not sure if any testing can be done on flywheel/ rotor to check magnetism. I'll be looking for another unit to check.

Darren.
 
DarrenO said:
Hello Robzerg,

I'm having the exact same issue. Same model bike. Except in Australia, went from bike running to weak spark then no spark.
I have brought all new components (coil, stator, CDI) checked all wiring 100 times over.
Now looking at flywheel
Not sure if any testing can be done on flywheel/ rotor to check magnetism. I'll be looking for another unit to check.

Darren.
Click to expand...
thank you for your answer !

I'm looking at the cdi side at the moment because by adapting taking crete measurements at the stator output, everything seems to be working.

My problem would come more from the cdi

i'm curious about the outcome of your problem, courage you'll end up finding
 
How are you checking the spark?

Don't go by a spark plug in the cap as they tend to pack up showing the spark really easily. try and use just the HT lead held away from the cylinder stud about 8mm and it should jump that IF you give it a cracking kick with the spark plug OUT of the cylinder head.

Someone here recently said he'd had a weak flywheel but that was a first. most of the time it is the plug getting buggered up with wet fuel and no spark being the end product.

Taffy
 
Taffy said:
How are you checking the spark?

Don't go by a spark plug in the cap as they tend to pack up showing the spark really easily. try and use just the HT lead held away from the cylinder stud about 8mm and it should jump that IF you give it a cracking kick with the spark plug OUT of the cylinder head.

Someone here recently said he'd had a weak flywheel but that was a first. most of the time it is the plug getting buggered up with wet fuel and no spark being the end product.

Taffy
Click to expand...
Thanks Taffy,

Personally I've already tried this and nothing has happened.
 
what are the readings in ohms from
red to black?
green to black?

cheers

Taffy
 
Hey Taffy

Does the regulator or rectifier have anything to do with spark operation?
I feel that something is earthing to frame but can't pinpoint. I will have spark for one or two rotations and then nothing for an hour.
Any advice on this would be great.

Thanks
Darren
 
no they don't. the green, red, black go directly from the stator to the coil.

where did you get your electrex stator?

you can't rely on the plug giving a good spark after its been in a wet cylinder.

Taffy
 
Ok
Stator is straight out of china,but only for testing as oringinal Sem is doing the exact same thing

I’m not using plug to check spark running coil lead stright to head stud

Thanks
 
OK well that is your problem. "straight out of China". we've all done it, nobody bigger than me; I bought three and they don't work. the readings are all wrong. You're meant to gt
red to black 2,700ohms
green to balck 165 ohms

but you get one right and the other is wrong. can't spark.

I have the right ones here in the UK and I supply the correct ignition timing which electrex don't.

Taffy
 
Yes I understand China can be a problem but just wanted a cheap comparison to start off with.

Original SEM stator red/black 6200ohm
green/black 192ohm

Chinese red/black 1200ohm
green/black 186ohm

I had a quick look at electrex site.
With your stators are they on your website? I can't find them.Looks like I'll be purchasing one .Also I may need to send you the coil/CDI as I have butchered mine (removed resin).
It's just the inconsistency of spark/no spark that's really getting me.

Darren
 

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