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Message started by greenmonster on 07/13/11 at 19:56:56

Title: Automatic backfire
Post by greenmonster on 07/13/11 at 19:56:56

So I've swapped out my engine from an 86 to a 95. It starts and idles beautifully. It is a wonderfully feeling to start rolling on the throttle and begin feeling at one with the road again. No more cage for me again.

Unfortunately, there is a small hitch.

Just as I hit the powerful RPM's the sucker starts to backfire like a machine gun.

Is this a result of not having swapped out my CDI/Ignitor or should I be looking at my carb?

Title: Re: Automatic backfire
Post by verslagen1 on 07/13/11 at 20:05:08

so is this a 95 engine with a 86 cdi?
if so, that is your problem.

Title: Re: Automatic backfire
Post by greenmonster on 07/13/11 at 21:01:00

That's what I figured. I have the CDI for this engine. Unfortunately it's a square peg into a round hole problem. I need to get a different connector for my wiring harness. (Either that or file off the edges to make the square peg round.)

Anybody know where I can find that connector? Even the model number of the connector body so that I can pick it up somewhere?

Title: Re: Automatic backfire
Post by verslagen1 on 07/13/11 at 21:22:28

It's either that or this...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1280002938

and you'll need one of these...
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310330145058&viewitem=&sspagename=STRK%3AMEWAX%3AIT

Title: Re: Automatic backfire
Post by greenmonster on 07/13/11 at 21:36:31

Thanks for finding that thread Verslagen. I remember reading it before and I couldn't find it today.

I already have all the stuff to do that swap. I also already have the CDI. I was hoping to change the CDI since then I don't have to rip apart my newly working engine.

By the way. That puller is a godsend. Anyone doing much mechanical work on this engine should get one!

Title: Re: Automatic backfire
Post by verslagen1 on 07/13/11 at 22:29:43

mine arrives tomorrow ;D

Title: Re: Automatic backfire
Post by splash07 on 07/14/11 at 09:31:55

I have been trying to get that connector for a while I finally decided that the easiest thing to do is just find a used wiring harness and canabalize it for what you need. A new harness is around 100 bucks.

Title: Re: Automatic backfire
Post by Serowbot on 07/14/11 at 10:06:50

Can ya' just cut the connectors off,... and use bullet connectors?...

Title: Re: Automatic backfire
Post by drums1 on 07/14/11 at 10:44:13

That's what I would do. A connector is a connector.

Title: Re: Automatic backfire
Post by Boofer on 07/14/11 at 19:39:05

I'm afraid I usually "twist and tape". :D

Title: Re: Automatic backfire
Post by greenmonster on 07/15/11 at 17:20:28

Unfortunately in this case the terminals are at the end of the module. There isn't any wire coming out of the Ignitor to put a bullet connector on. I'm starting to think about solder though.

Title: Re: Automatic backfire
Post by greenmonster on 07/15/11 at 17:30:02

Anybody have a good diagram of what the new Ignitor lines up as? I've found the older diagram. It gives me - - - - - - - - -

but my new ignitor terminals are:
- - - - - - - -

I'm a little confused about what to wire where.

Title: Re: Automatic backfire
Post by verslagen1 on 07/15/11 at 18:51:01

part 1...

5C6578677663747F727C170 wrote:

As from page 5-7 of the Suzuki Savage WSM.

Greetz
Kropatchek ;D

http://img277.echo.cx/img277/8531/igniterunit6bl.jpg

Title: Re: Automatic backfire
Post by verslagen1 on 07/15/11 at 18:58:00

part 2...

202439393B67616160560 wrote:

1997 Ignitor

1: Black/Yellow tracer -> ignition coil;
2: Black, no tracer -> starter relay
3: no wire
4: no wire
5: Orange/White tracer -> ignition coil & kill/start switch = + 12V
6: Green, no tracer -> magneto pickup coil
7: Orange, no tracer -> magneto pickup coil
8: Black/White tracer -> ground

http://i55.photobucket.com/albums/g152/vroom1776/Ignitor_1997_LS650.jpg

Title: Re: Automatic backfire
Post by greenmonster on 07/15/11 at 22:19:58

Part 2 is exactly what I need. Thank you very much!

Vers and everyone who helps out on this site is amazing.

Title: Re: Automatic backfire
Post by greenmonster on 07/18/11 at 10:09:21

I was able to find some female disconnects that I made fit onto the new CDI. Everything is running smoothly now. It seems to be popping more than the old engine but I imagine that's something that I can sort out with a little tweaking and some of it may be dealt with when I put on the dyna pipe.

Thanks for all your help everyone.