82 650 GL needing help Plugs are not firing

[esmithers]

Okay before i explain.. i have read over and search through the site the best i could to try and solve this but i am lost at whats the problems.

problem: plugs will not produce heavy healthy spark or not spark at all. they are all intermitting the spark and are not healthy of a spark when they do. Every once and while the bike will puff black smoke but never fire up.

What i have done: Changed the Stator, R/R unit, Coil relay mod. i have cleaned up the wiring and made sure there are clean and solid connections to include additional Grounding to ensure proper grounding.

I have looked at the Signal generator and it seems to look good. the coils have 11-12 volts going to the + and i tested the resistance on the + and - terminal and have a reading of fluctuation then settling to 5.9-4.8 setting on 200K.

WHAT GIVES???? what could possibly be the problem.

PLease let me know what you think.. thanks

[BigD_83]

Have you checked the spark plug leads?

[esmithers]

Yea i have cut off the ends and cleaned the connections in the boot

[esmithers]

I am thinking the igniter is bad, i ordered on from Ebay, hope this corrects this issue.. if anyone has any other suggestions please let me know..

Update, i went out there to check everything and the plugs were sparking but then it stop sparking. could this be a thermal breakdown in the ignitor

[tom203]

Do the Mr. Matchless tests in this link....

http://members.dslextreme.com/users/storagecliff/images/electrical_odd-n-ends.html#A17

Your ignitor (along with R/R) is mounted on plate under air filterbox- try running a jumper wire from this plate to battery negative- make sure you have good contact. Check/clean connector plugs from ignitor to signal coils and from ignitor to ignition coils.
A bad stator and/or R/R won't cause weak/no spark- if it cranks smartly the plugs should fire.

[esmithers]

i have removed the wiring from the bike cleaned it, additionally replacing the bullet style connectors with blade type. i have made sure i have great earth connections and have ensure connections are connected. this is a matter of a part and not wiring issue. I have replace both the R/R and Stator and now i am going to replace the ignitor to remove doubt. if this does not work i will just sell the bike or part it out.

[tom203]

.........now i am going to replace the ignitor to remove doubt. if this does not work i will just sell the bike or part it out.

Wow, how do you know this ebay ignitor is any better than yours- neither will work if you got a connection problem. This model ignitor is tough- probably high voltage from bad R/R would kill it but it ain't likely to wear out. I've tested 3 on my bike and they were fine- sold one to a Florida guy in April .

[esmithers]

Guy said that this thing was running when it took it off and sent me the pic of the bike that had been in a accident showing it running on a stand...

[tom203]

I responded to your PM- I'm suspicious of your repaired ignition coils as reason for no/poor spark. Go to that link I mentioned, note step 10 (testing the ignition coils). Coil sets are cheap on ebay - your ignitor ebay seller might have some- because they don't usually fail especially if they haven't been monkeyed with.

[esmithers]

Coil sets are cheap on ebay - your ignitor ebay seller might have some- because they don't usually fail especially if they haven't been monkeyed with.

Update. The Ignitor was infact the issue. it shown perfect to ohms and only think i can guess is that once it was getting juice it warmed up enough to have a thermal breakdown. So like i had stated, eveything else was check and this part was the only one to make sense on changing and i am sure glad that was it.

Now, the bike runs like shyt and hard to crank. I need the air filter plastic or metal what ever that my foam filter wraps around. additionally i need to take my carbs off again and ensure mine are good and cleaned.

i am happy to have this 12000 mile bike. all i have to do now is fine tune and get it to idle and run correctly.

[BigD_83]

Glad you got that sorted out.

Hard to start? Have you checked and adjusted the valves yet? If not, that is the first step, before pulling the carbs.

[recycled64]

Air filter

The air filter 'cage' is sometimes, but very rarely, available on Ebay. Part #13780-34200 is available on Boulevard Suzuki's website, includes the filter and cage, for $27.88. Not cheap, but that's all there is at the moment. Think I'd get that taken care of before anything else, these intake designs are really sensitive to the slightest air intake anomalies, and what you're lacking, the cage and proper filter fitment, is major.