Ignition failure? Problem solved...?

-ahven- · August 20, 2009, 03:54:00 AM

What's happening?

I was driving 50 mph on highway when engine stopped running for few seconds, then it started again with big BANG from exhaust and runned normally. I stopped and engine sounded normal, response to throttle was normal, everything worked as should. After that same happened occasianally. I stopped again took a brake and smoked couple cigarettes. After that it worked normall all the way to my garage (10 miles).

Is it ignition problem or what? Overheat? Too lean mixture?

-ahven- · August 20, 2009, 10:40:54 AM

Am I the only one? Today problem repeated. Can it be crap in carbs? I'm going to open and clean my carbs again, hope it helps...

jeremy_nash · August 20, 2009, 11:53:38 AM

sounds like a problem on the spark side, there is a backfire when it comes back on, so that would indicate fuel is still flowing. check grounds, corrosion at coils, and tightness of the coil wires

-ahven- · August 20, 2009, 02:57:32 PM

But it also can be problem with carbs, am I right? What is the weakest link of ignition system? I'm so confused with this issue right now...

PachmanP · August 20, 2009, 06:48:22 PM

it doesn't sound like a carb problem. If you felt like it you could check your spark plugs to see if you're running really rich or really lean, but I would think that you wouldn't restart or get the backfire if that was the case. You could be vibrating something loose and it just reconnects or something. Electrical problems are a pain in the butt, though.

bill14224 · August 20, 2009, 08:00:02 PM

I agree with the others. It's an ignition problem. Your plugs weren't firing so the exhaust filled with fuel/air mixture leading to the backfire. You have an intermittent electrical connection somewhere that's knocking out your ignition. Check the connections first in the harness connector on the front left side of the bike. Several others here have had ignition problems because of connections there.

-ahven- · August 21, 2009, 05:32:20 AM

Other crank trigger seems to be little melted. Could it be the reason? What is the part code for that piece and is there same trigger on any other bike model?

Yesterday when I was driving, engine stopped running just like before but it didn't make that "BANG" in exhaust anymore. Today bike worked pretty good. Only after 20 miles rides when accelerating on sixth gear from 50mph up bike "tugged" a little. If it's not the ignition problem, can it be a problem with gettin gas on higher revs? I assembled in-line fuel filter when I rejetted, can it cause such a problem?

gsJack · August 21, 2009, 06:44:12 AM

My first thought reading your post yesterday was that it was an ignition problem as others have said but I can get a similar backfire trying to start my bike in the winter when it's very cold when the accumulated gas in the exhaust finally explodes while cranking before starting.

First make sure all connections are tight including the harness connection suggested above. Check to make sure the spark plug wires are tight in the coils, I've had that problem on my 02 and the bike will hardly run with one cylinder cutting out, very hard to get it up to 50 mph that way.

I would be suspecious of that inline fuel filter you've added as many others have, I've had a car that cut out and stopped after going at higher speeds a short distance when fuel ran out and would run all day at lower speeds requiring less fuel flow and it was caused by a faulty inline fuel filter. I've gone 150k GS miles without adding a fuel filter beyond the oem one in the tank and never had a fuel problem.

That burnt pick-up coil sounds suspecious. I checked and it's sold as a signal generator assembly 33110-44420 for about $140 from Ron Ayers and the part number is same for both 89 and 02 models but there is a different single coil one for 04 and later. A good used one from a 89-02 model would work if that's the problem. You didn't say what year or miles on it you have.

-ahven- · August 21, 2009, 06:49:04 AM

Thanks Jack. You mean it's 140 $ for that little black thing: http://i8.photobucket.com/albums/a28/-ahven-/Muut/21082009602.jpg

gsJack · August 21, 2009, 06:53:45 AM

It's $140 for the whole assembly, both coils, plate, and wiring.

http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/30/Year/1989/ModelID/6312/Model/GS500E/GroupID/259239/Group/SIGNAL_GENERATOR

Those long urls sure mess up a thread.

-ahven- · August 21, 2009, 07:43:38 AM

Pretty expensive part... And I think it's hard to find it here in Finland. Don't know if it's worth of buying that new signal generator if it is not a reason for my problem. Inline filters work very weakly with GS, I've noticed that. First one I installed in spring and it won't let gas trough even on idle. This new one should be "high-flow" filter but I don't know if it's enough.

It's weird that my problem only comes when driving ~50mph on. Everything is normal when driving slower.

gsJack · August 21, 2009, 11:33:02 AM

Remove the inline fuel filter and try bike without it to see if it's the problem.

-ahven- · August 21, 2009, 12:50:09 PM

Quote from: gsJack on August 21, 2009, 11:33:02 AM
Remove the inline fuel filter and try bike without it to see if it's the problem.

I'll do it tomorrow. It's last warm days here in Finland, so I hope I can get on the road again before it's too cold...

-ahven- · August 22, 2009, 01:33:41 PM

Today I removed that in-line filter, replaced spark plugs, caps and wires(sparg plug wires were in VERY weak condition), cleaned up ignition coil terminals and checked all wires coming to coils. Also there was loose connection on that thin wire that is attached on minus pole of battery, so I replaced that whole wire.

Drove 50 miles and bike worked perfectly. Don't know what was the main reason but I'm happy that it's ok now.

Happy, happy, joy, joy

I'm on the road again!!

erbilabuc · August 22, 2009, 09:13:39 PM

i know you fixed it but just to say that same thing happened to me and there was a small stick on my kickstand and yep when I was driving it would shut off then loud bang (backfire) and back to normal.......

-ahven- · August 23, 2009, 01:17:46 AM

Yeah, I also had loose kickstand and tightened it also yesterday. Not propably the reason for my problem but can cause new one some day.

bill14224 · August 23, 2009, 06:25:53 AM

Loose ground to battery = no ignition. You fixed it, yea!

-ahven- · August 23, 2009, 12:48:29 PM

Quote from: bill14224 on August 23, 2009, 06:25:53 AM
Loose ground to battery = no ignition. You fixed it, yea!

I feel so stupid if that little wire caused my problems. I broke up almost my whole bike to find a reason

But now I have plenty of new parts installed, new fuel lines, sparkplugs and other ignition stuff... Was worth of tears

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Ignition failure? Problem solved...?