No Spark - Suzuki 1999 DR350X

[Drogen Omen]

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]

So when you kick it over with the plug out you still see no spark?

[Drogen Omen]

when i kick it over the lights come on and Indicators work but now spark at all even with the plug out.

[barty5]

bad earth check earth from coil??

[cheese]

Maybe the spark plug lead?

[awayatc]

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

[Drogen Omen]

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]

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]

http://www.dropbears.com/bikelinks/P...ycle_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]

Shit, what a disaster mate ... a good auto electrician (M/C) shouldve be able to nail the fault in no time ... sounds weird.

[avgas]

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]

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]

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 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/houseofmot...x-1999/o/m5865

[Drogen Omen]

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]

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.