Stalling Out - Won't run for more than a minute

[CoryPro]

So long story short, I was out riding with my brother yesterday when we were fooling around in some gravel pits and my blaster just stalled out. I couldn't get it started again. He rode back to grab his truck and I started walking.

When we finally got back to the blaster, I noticed that the 4 wires coming from the stator were "welded" to my exhaust pipe. The plastic was singed onto the pipe, thus grounding out a wire. I managed to peel it off and the bike started, but ran for only a minute.

Fast forward to this morning, I went to the store to grab a soldering iron, solder, and wire and disassembled the bike to take a look at my stator plate. Last time the bike stalled out it was because the ignitor coil had been soldered on poorly. Since I fixed that, I had absolutely no problem until now.


I managed fixing the one wire that was burnt and rerouted the wiring around the exhaust pipe to prevent the same thing from happening again. I also did a better solder job on the ignitor coil and the bike started up fine.

About 30 seconds into riding it, it kept trying to stall out. If I didn't give it throttle, it would have died. After a full minute it completely died out and I could not get it started again. I waited a minute and kicked it over, and it ran fine.... for about another 10 seconds. It seemed that the longer I waited before starting it up, the longer it would run but, it never ran for more than a minute.

I've triple checked all the wiring, unplugged everything and put it back together, checked for breaks, grounds, and any other possible electrical problem but Im out of things to check.

Does anybody have a clue what may be happening?

 

[Scrappy]

May be a stupid question but are you sure you got gas in it? And if you do pull the fuel line off the carb and turn petcock to on position and make sure it is flowing the way it should. Cause it sounds like it is starving for gas.

 

[xJust_Causex]

May be a stupid question but are you sure you got gas in it? And if you do pull the fuel line off the carb and turn petcock to on position and make sure it is flowing the way it should. Cause it sounds like it is starving for gas.

Also on a side note, try running it on the reserve setting instead of the on position, I had problems with my doing that before, next would probably to tear into your carb and clean it.

 

[125pb]

maybe the TORS??? if it is still hooked up

 

[hudack]

cold be not geting enough gas try pulling ur fuel line and see if it flows enough if not put it to res if that dont work clean ur gas tank sounds like it could be filling up the carb then when u run it runs outa gas then u let it sit starts the cycle all over again

 

[blasterfreek30]

all this happened after the wire melting.....i would say its still in the wireing somewhere

 

[CoryPro]

[edit] I apologize for the delay in my response. I wrote this post out at the cabin, where I have no internet connection. I drove a few kilometers to where I have a hotspot, but after I made home, my car died on me =/. Just my luck [/edit]


Alrighty. After two weeks of it acting up, here's where I'll start.

Recap:

- Bought the Blaster in March, no spark
- Replaced: Charge coil (was the culprit) , Lighting coil, CDI, Ignition Coil, and Voltage Regulator
- Blaster kicked over and ran beautifully for two months
- Blaster stalled out 4km in the middle of the bush.
- Removed the flywheel to see the solder on the charge coil came off. Replaced the solder with a better job and added a secondary wire as a fail-safe
- Blaster ran beautifully until riding it in the bush in the same area it died before. Found out the black/white wire from the stator melted (not much) onto the exhaust.

Since then I have taken a look at the following and tried this:

- Gas was replaced. When it died, I had just put it a fresh tank, 32:1 of premium. Swapped it out with new gas. I ran it on on the reserve tank and on normal. There was no difference in how long it would stay running.

- The TORS was removed before I purchased this Blaster

-I took off the stator, re-soldered all the connections with a 100w soldering iron. I spent 3 hours doing a real good job and checked all the connections with an ohm meter. I would have to say that the stator plate looked like it could have come from the factory when I was done with it. I also double checked all the wiring for breaks from the stator to the CDI unit. Everything was 100% perfect and in correct working order.

- Upon dismantling, I did not use a puller on the flywheel and thus broke the casing (by accident). Not a big deal, but what I did notice was that the piece I broke off stuck to the flywheel when I pulled it off. Without thinking, I pulled the piece off the flywheel and threw it away. Needless to say, upon fixing my stator plate I soon ran into my old friend Murphy. That piece I thought was from my casing was actually the flywheel key. I spent 5 hours looking for it. I even set up a rope fence from what looked like an archeological dig. I ended up making one which took a few hours but did the job. I kicked it over and it ran for about 5 minutes. I drove it very slowly and carefully but it still died. I wanted to take a video of it but decided not to. The best way to describe what it's doing is like this. I drove it and pulled out the choke, then it stalled. This is exactly what it feels like when it dies on me. I can open the throttle as it's dying and you can hear it sound more 'throaty' but it just won't accelerate.

- I made certain that the new flywheel key worked and was doing it's job. There was no slipping of the flywheel under acceleration.

I'm at my wits end here and have replace all the electrical units except for the stator coils and this problem persists. It all started when that wire melted to the exhaust =/.

 

[brandoz28]

are the coils on the stator within the ohm specs?

have you tried a fresh plug? you may have fouled that one, especially if you were just putting around for a while

 

[CoryPro]

I never did replace the plug but did suspect that could be the problem. I just found it awfully weird that the thing would run like a beaut, then all of a sudden quit out. If you would wait 10 seconds, it would start back up just fine and run again for another 30 seconds before it quit out again.

 

[brandoz28]

start simple, try a fresh plug

 

[xJust_Causex]

plugs are devilsh thinks. We took off riding one day and was playing in the creek and I thought that I sucked in some water cause the blasty would not start, and if it did you would have to bascially keep it at full throttle and even then it would pop and sounded horrid and would die in short order. Well I got drug home and put a new plug in, fired right up and has been running like a beast ever since, needless to say I carry a fresh plug and plug wrench with me all the time now

 

[CoryPro]

Alright. I know it's been a while but I'm back at my cabin and I managed to get some work done. I started by trying a new plug and taking it out for a ride. The performance helped it out a bit but not by much. It took 30 more seconds out to stall than usual. At my wits end with this thing, I pulled the carb off thinking maybe the float was stuck. Nope =/. I cleaned the whole thing out and checked to see if there was something in the gas tank...... Nada.... I put it all back together, unplugged every wire and I was still dying out. One strange thing I ran into was this. With my multimeter, I was looking to see if anything was grounding out when it shouldn't be. Coming off the stator plate, when checked with an ohm meter, my y/r wire and w/r are connected somewhere. I looked at the wiring diagram and from what I can see, it shouldn't be. Besides that, I'm completely lost as to where to look next