SuzukiSavage.com - Test Ride Cut Out on me xx!#%@>

Savageman

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Test Ride Cut Out on me xx!#%@>
06/19/16 at 23:24:06

Well I got the engine installed after a complete top end rebuild. I put new piston and rings, honed cylinder, new rockers, new cam chain, hand lapped the valves, and a new tensioner. Rejetted the carb and replaced the fuel petcock. Installed a HD Dyna muffler. Cleaned all connectors and applied silicone gel.

So I put in the oil 15w-40 Rotella synthetic with some redline top end lube. Add about 1 gallon of gas install the battery (has been on trickle charger.) Turned on the key hit the starter and 2 comp strokes fires right up and sounds good.

Took it for a test ride and got about 5 miles from home and she just shuts off. Cranks and nothing. I let it sit for about 15 minutes and crank it and it fires up. So I turn around and head home. After 5min it shuts down again. Angry

Then starts up and i get it home confused. Looking at all the wiring and a good look over. Then with the flashlight I see bare copper on the wiring harness coming from the stator/ignition p/u coil. The belt has cut through the wires but with a small gap on the green wire. A make and break connection. I FOUND THE PROBLEM!!! Cool

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #1 - 06/20/16 at 03:38:09 You're not the first one to have that problem....the good news is that you did make it home!
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Test Ride Cut Out on me xx!#%@> Reply #2 - 06/20/16 at 13:04:05 Yep, routing in that area is critical. Why did you need a new tensioner? What did you do with the other?
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Savageman Senior Member Offline Knowledge is half the battle Posts: 275 Marysville, California Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #3 - 06/20/16 at 13:56:55 I'll send it to you if you want it. JOG
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engineer

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Re: Test Ride Cut Out on me xx!#%@>
Reply #4 - 06/20/16 at 14:29:50

Sounds heat related and I have to wonder about the piston and ring fit. Did the engine slow any before it stopped. Here is one possible theory. In my experience if a slightly too tight piston/ring seizes up an engine it tends to first slow down, fairly quickly but long enough that you can feel the revs and torque drop. Then when it cools a little it is ready to go again. You might want to do several short rides, short enough to avoid the stoppage to help wear in the rings. Then gradually do some longer rides.

But you said it will crank right after shut down. That would be odd for a seized engine unless that starter has more torque than I would expect.

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2005 S40, Intruder shocks, Dyna, 52.5/150, 3 washers, 2 turns, modified seat, Raptor

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Test Ride Cut Out on me xx!#%@> Reply #5 - 06/20/16 at 14:35:17 I think that tensioner has been sufficiently stressed. Thanks for the offer, though. How many miles were on it when you figured that out? I don't understand how that kind of wear got on it..
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Savageman Senior Member Offline Knowledge is half the battle Posts: 275 Marysville, California Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #6 - 06/20/16 at 14:35:37 No it didn't seize up the belt cut through the wire harness from the stator ignition pick up. Read my little story over again.
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Savageman

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Knowledge is half
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Marysville, California
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Re: Test Ride Cut Out on me xx!#%@>
Reply #7 - 06/20/16 at 14:41:47

JOG- I bought the bike that way with a busted timing chain for $350.00 a rescue bike. The previous owner was a complete idiot when it comes to mechanical issues. He said it was making a horrible clattering sound then just went clunk. D'oh!

So anyways i bought it and rebuilt it. Now I have to fix the dam wiring harness that the belt sliced through.

With new rings and a valve job it has some torque! Cool

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Test Ride Cut Out on me xx!#%@> Reply #8 - 06/20/16 at 14:44:50 clattering sound then just went clunk. D'oh! That's pretty dang funny.. Sounds like you've done well.. and rescued a deserving critter.
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engineer Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 872 Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #9 - 06/20/16 at 17:55:16 Sorry, I've got to read these posts all the way through! Cut wires are a much better outcome than seized up piston!
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Savageman Senior Member Offline Knowledge is half the battle Posts: 275 Marysville, California Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #10 - 06/20/16 at 18:52:51 Yep. The engine runs beautifully and strong! But still needs a spark to run. Dam.
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LANCER Serious Thumper Alliance Member Offline Savage Beast Performance Parts Posts: 10667 Oklahoma Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #11 - 06/20/16 at 22:52:37 Savageman wrote on 06/20/16 at 18:52:51: Yep. The engine runs beautifully and strong! But still needs a spark to run. Dam. Funny how that is ...
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #12 - 06/21/16 at 04:44:43 Savageman wrote on 06/20/16 at 13:56:55: I'll send it to you if you want it. JOG http://i.imgur.com/kVVZ26B.jpg I wouldn't be able to use that tensioner.....it is far to big to fit in my engine - it won't even fit on my computer screen!
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Test Ride Cut Out on me xx!#%@> Reply #13 - 06/21/16 at 04:49:38 DAVE! That's the funniest thing I've seen in quite a while... Now, you stop that. You're supposed to be helping people. I'm supposed to either piss them off or make them laugh.
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Savageman Senior Member Offline Knowledge is half the battle Posts: 275 Marysville, California Gender:	Re: Test Ride Cut Out on me xx!#%@> Reply #14 - 06/21/16 at 08:08:59 You guys are so funny i can hardly even believe it! You can see all the detail though hi res lives!
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