Hello,

Hope to get some suggestions on my next steps for troubleshooting.

Here is the story:
Bike was running just fine, the bike started and ran for about 1 block then for no obvious reason it just lost power and stalled.
Now, the bike does starts, but struggles to stay on... after the bike stalls, there seems to be white smoke/fume that comes out of the air box.

The following is what I done to find the issue:
- I made sure the valves are to spec, by putting it on TDC and adjust valves clearance to .5
-Took the top of the case off to check on the chain and timing... I looks fine.
-Compression test was in the low 100.
-Pull carbs apart and clean all components.
-New carb diagram… replace awhile a go.
-Petcock is a brass fitting, open and flows with no problem.
-Tried 2 different spark plugs.
-There is no apparent oil leak.

I recently simplify the starting wiring system, in the process I put in some new staff (new solenoid, new coil, new spark plug, new(used) CDI, new pickup coil, new stator, new negative wire to case)

Any Suggestions on what my next step may be troubleshooting wise?

I will try to take a video later today, greatly appreciate any suggestions.

PerroVivo wrote on 04/12/18 at 10:18:32:

Have you drained the airbox?
Quote:

Usually a sign of too low of an idle speed or bad valve adjustment or sticking valve.

Sudden stalling, I would check the safeties, clutch, kickstand and neutral.  A bad connection here can shut it off in an instant.

"took the top of the case off to check the chain and timing " ???? do you mean the right side case? ( you could check the timing by looking at the line on the cam gear, but you need to check the chain and tensioner by removing the right side case.)     Were all the components you changed in the electrical  system,  stock Suzuki? Can you supply a drawing of your present wiring system? Your compression seems low for a stock bike ,did you use an after market cam? Is the carb stock ? What size jets are you running?

Your wiring diagram doesn't make sense. What supplies power to the starter switch and the coil and TDI ?(missing wire) what does the key shut off besides the regulator? How does the regulator monitor the battery voltage so it knows when to shed power to ground?(missing wire) You need to do a bit of research. and I'd only use a stock TDI and Coil as they are designed to work together and changing either could cause damage. You might look in the Tech Section and find a better working diagram. It should include the kill switch as this is one switch that  should NEVER be bypassed.(if you go down and the key brakes off you have no way to shut off the bike)

It's common to say CDI which stands for capacitor discharge Ignition
TCI is what we have, Transistor Controlled Ignition.

I believe what the diagram should be...

batman wrote on 04/13/18 at 14:32:58:

Most modern reg/rec combine the 5th and 6th wire.

I think only the 88 I have had all 6 wires.
the 96 01 and 02 all had 5.

If your going to vote in the poll, don't guess, pull your seat and look. If there isn't six wires ,send me a crow to eat (cooked well done).