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Drogen Omen
7th August 2008, 12:09
I Have a Suzuki 1999 DR350X (dual purpose road legal model), it has no spark.

I have replaced the CDI at a cost of $1000 NZD
Have reconditioned the Stator
Have changed Spark plug.
Have rewired the whole bike.
Have tested the Capacitor charges up to 12v (the 1999 model X has no battery).
Reg/Rec seems to be working properly but have also tested it with one out of another DR350.
Have tested with a 12v battery and bypassed the capacitor.
Have triple checked the kill switch and kick stand kill switch.

After all of this i still have no spark, and been 9 months without a bike...
I'm getting withdrawal symptoms guys....
Got the shakes and cold sweats...

I'm stumpt...

any ideas or hints guys...?

avgas
7th August 2008, 12:24
So when you kick it over with the plug out you still see no spark?

Drogen Omen
7th August 2008, 12:40
when i kick it over the lights come on and Indicators work but now spark at all even with the plug out.

barty5
7th August 2008, 13:06
bad earth check earth from coil??

cheese
7th August 2008, 13:15
Maybe the spark plug lead?

awayatc
7th August 2008, 13:33
haven't you got 2 stators?
one for ignition and one for Auxilaries...?(lights etc)
The live one from ignition stator is usualy black red....does that one spark when you put it close to naked metal/earth?

i once had the pick up fail on my DR 250....the insulation from the wire had been damaged by the flywheel......

If you have spend $1000 on a CDI that may not even have been faulty, you may take the bike to your local friendly auto electrician......can't cost much for a diagnose.....
Good luck

:scooter:

Drogen Omen
7th August 2008, 13:57
earth from coil checked and ok.

forgot to add that i also got a new top end lead from spark plug.

bike only has one realy big fuckin stator that powers the whole bike. there are 2 pickups coming from there one powers the lights the other goes to big ass 12v Capasitor that charges up to 12v and starts teh bike when it discharges.

insulation to the pickups has been re-done. but still no spark.

bike has been with Auto Electrician for last 6 months and still no luck.

Drogen Omen
7th August 2008, 14:03
done everything i can think of apart from Replacing the Stator as its $850 for a new one.

pickups come as a package with the stator and you cant get them seperatly acording to Wellington Motorcycles...

checking Trademe and eBay for second hand stator and puckup units but still no luck for my 1999 DR350X.

barty5
7th August 2008, 16:04
http://www.dropbears.com/bikelinks/Parts/Salvage_Yards/Australian_Motorcycle_Wreckers/
try this link and use the finda part works real well
or just email this guy check out their web page dirt bikes is what they do have used before real helpfull and almost allways have what you want. $$ not bad either

tony@justdirtbikes.com.au

secondfield
7th August 2008, 16:48
Shit, what a disaster mate ... a good auto electrician (M/C) shouldve be able to nail the fault in no time ... sounds weird.

avgas
7th August 2008, 16:55
Check conductivity/resistance of each part separately - sounds like you have lost a connection somewhere.
I am also assuming that the CAP hasn't popped - creating an open circuit.

barty5
7th August 2008, 18:14
i have a pfd file at home full factory manual (dr250) but im sure there wont be much difference ill email it to you so you can double check wiring etc.

T.W.R
7th August 2008, 18:54
Have you got the correct air gap for the exciter coil ?? ( Don't try checking or setting this by feeler gauge either otherwise you'll get a false measurement every time :yes: a piece of paper folded in two is ample clearance & it also follows the curvature of the assembly unlike a feeler gauge). Is the exciter coil OK ??

As for a stator you can source one via bike bandit for $364.39 (P & P additional)

http://www.bikebandit.com/houseofmotorcycles/suzuki-motorcycle-dr350x-1999/o/m5865

Drogen Omen
7th August 2008, 19:24
Sweet thanks guys for all your help.

Taking it in to Wellington motorcycles next week to get them to fault find it. $80 per hour. just need them to find the problem. hope they can find it since they are the Suzuki experts.

will get any parts i need from those websites.

will let you know how i get on... aparently its a more common problem with the 1999 series X model DR's. found a couple more forums with same type of simptoms.

my dads mate also has the same issue but with the battery version 1999 Dr350X SE.

Drogen Omen
15th August 2008, 10:42
Wellington Motorcycles has confirmed that its the Stator that is the problem and it only took them 2 hours to do it. compaired to TSS who had it for 4 months and still couldnt find the problem.

$50 and a crate of beer to any one who can find me a second hand stator unit for a 1999 DR350X. there must be some out there.
remember it has to come from one that doersnt have a battery just like mine.

im supper skint at the mo so brand new one is out of the question.

with the NZ dollar the way it is even that new stator from Bikerbandits is a bit expensive after conversion and shipping comes to about $720 NZD so only save about $100.

secondfield
15th August 2008, 11:42
You'd be wanting to get a refund for the 'reconditioned' stator then mate ...

barty5
15th August 2008, 11:57
should have answer on where one might be later today ill let you know.

merv
15th August 2008, 13:12
You'd be wanting to get a refund for the 'reconditioned' stator then mate ...


.... and sell your spare CDI unit.

theblacksmith
17th August 2008, 08:59
I'd put a wanted ad on Trade Me as well.Hope u get it sorted mate.

Drogen Omen
28th August 2008, 06:57
apparently this sort of thing is quite common with the 1999 X series DR350

reason is that they have no battery so have an extra large Stator/Magneto and are air cooled... due to this issue of only being air cooled they tend to overheat and can sometimes warp the magnets which changes the polarity and outputs a different voltage.

if voltage is changed and outputs a higher voltage the regulator/rectifier fixes this and bikes still runs, but if voltage output is lowered then this results in no spark as the regulator/rectifier cant fix this and therefore kills the connection.

so if you have a DR350 that has no spark and you have replaced everything you can think of... the Stator will most likely be the problem.

cynna
27th March 2009, 09:39
how did u get on

my 99 dr350x is now in the shop with the same problem. did u buy a new stator or get it rewound? was that all that needed doing or were there further problems also caused

looks like there is no cheap way around it

Dave Nevin
25th March 2011, 21:45
Hi, just bought a '98-99 dr 350 :-) Found this old thread, so what happened to 2 bikes? Wellington, and someone's uncle?

Mine runs if the regulator is not plugged to loom. Does not run if regulator is plugged Orange and b/w (2 pin plug).
Has varying AC volts in 3 yellow wires from alterator/magneto.
Regulator gets warm if plugged to 3 yellows.
If I kick it over, neutral and tail lights will come on briefly..

Have ordered 'new' regulator and stator, so will plug one at a time..
Any other thoughts?

Want all electrics so I can ride it on the road.

Dave in soggy Whangarei

Shadows
26th March 2011, 08:48
Good luck - mine's been at the auto sparky for almost a couple of months now :(

Fucken Jappas, I shoulda known! It's all part of their master plan, they've purposely flooded the market with dodgy electrics to drive the white man insane. Once we all become frustrated quivering messes lying around on the ground drooling they're going to stroll in and take us over.