my SG started running like garbage out of nowhere...

[ERM83]

OK...a little over a week ago, I got caught in the rain/drizzle/mist on the way to my work's xmas party. we've had a LONG spat of crappy, rainy weather here. I got 3/4 of the way to my work (which is a 6-mile ride), and the bike started puttering and dying unless i revved it past 3,000RPM.

I figured at first, maybe i'm low on gas (my sensor is starting to crap out). stopped at the gas station, checked my fuel lines, put PLENTY of gas in, started it back up, and it was fine...until i tried to pull out of the gas station. it once again felt like it wasn't firing on all cylinders, so i had to park it and walk the last mile to work. got done there about 3 hours later (it was still misty and drizzling), and got it to my bud's house about a mile away with no problem.

the next day, it was a bit foggy,and i started riding home with ZERO problems. got about a mile and a half from my house, and the SAME DAMN THING happened again. it's home now of course, but this problem made it a TWO DAY PROCESS TO GET THIS THING HOME.

i've looked up the symptoms and solutions on here...there's a multitude of possibilities as to what it could be, so i started with what i'd been meaning to change out, and had them just waiting in my dresser to be put on: PLUG WIRES. maybe a wet connection?? ballast resistor wires?? NOPE.

JUST changed out my plugs and wires (the accel wires), started'er up, and all seemed fine...THEN, after a couple minutes of warming up, i blipped the throttle, and....SAME. FRIGGIN'. DEAL.

i'm about to do the spray test on the headers, and i also have my multimeter to check the CDI, electrical connections, etc.

here's some pics of the spark plugs...definitely strange. they DID NOT look like this when i changed them in september...they looked normal. also, my carbs were cleaned/rebuilt this summer, if some of your remember my debacle with those a few months ago. that makes me wonder what's happening here...super strange...

here's plugs for cylinder 1&2, left and right respectively (i see that cyl. 1 is WAY rich...):



here's 3&4...notice how 4 is REALLY clean, and 2/3 wore the same way?! COILS SHOT?!



one last thing: being that i occasionally have a SLIGHT gas leak out of the inlet of carb #1, is the float level off???

will report back in a few minutes!

[BA80]

The pickup coil connector behind the fuse panel is the culprit I would bet. For some reason it seems to collect moisture and short the pick up signals.

I filled the plug with dielectric grease and haven't had the problem ever again.

[ERM83]

The pickup coil connector behind the fuse panel is the culprit I would bet. For some reason it seems to collect moisture and short the pick up signals.

I filled the plug with dielectric grease and haven't had the problem ever again.

so, i did the header water spray-test...1, 2, and 3 are fine, but 4 wasn't even hot at all...i could touch the pipe without even remotely burning my hand. stops firing as soon as the engine starts to get even relatively warm..

Eric

[BA80]

Check that plug I mentioned and be sure the spark plug resistor caps are making contact with the wire core.

Those caps unscrew from the wires. Just cut about 1/4" off the wire so some of the fresh core is exposed and screw the caps back on.

I'll almost bet it's the plug but it could be the other too. Won't hurt a bit to re establish good contact in the caps either way.

[ERM83]

changed all the plug caps as well...

Check that plug I mentioned and be sure the spark plug resistor caps are making contact with the wire core.

Those caps unscrew from the wires. Just cut about 1/4" off the wire so some of the fresh core is exposed and screw the caps back on.

I'll almost bet it's the plug but it could be the other too. Won't hurt a bit to re establish good contact in the caps either way.

i have to check on that plug that you mentioned...however, the PO "modded" the fuse box, and it's a friggin' mess....which plug/wire am i looking for?? i've been trying to figure out what you're talking about...can't find anything!

[MaximPhil]

Hi ERM 83,
While BA80 is explaing the connector which is a likely culprit.
I had a similar experience with a cracked coil that would do exactly that in the wet.
Only found it after changing the coil and a good clean and close look in bright light to see the hairline crack.
Phil

[BA80]

You have to take the 3 big phillips screws that hold the fuse panel mounting plat on and pull it back to expose the rectangular plug. It's made for 6 wires but it only has 5 with one blank hole in the center 2.

Looks like this.......

[BA80]

Hi ERM 83,
While BA80 is explaing the connector which is a likely culprit.
I had a similar experience with a cracked coil that would do exactly that in the wet.
Only found it after changing the coil and a good clean and close look in bright light to see the hairline crack.
Phil

That's possible too but let's K.I.S.S. for now and not head in 40 different directions.

[ERM83]

i thought i posted last night, but guess it didn't go through?!

anyway, here's where i'm at: did exactly what greg said...cleaned that connector(s), put some dielectric grease on there...NOTHING, still. i brought my TCI inside...gonna check that in a sec. i'm leaning more towards a bad/cracked coil....

Eric

[BA80]

Did you check the connection on the resistor caps like I said?

[ERM83]

Did you check the connection on the resistor caps like I said?

Yeah, I did that before I changed the wires/caps. Everything checked out right. I also checked the wires with a spark tester...lights right up on every cylinder. I yanked the carbs, as the spark plug on #4 looked WAY too clean...thought maybe it just wasn't getting fuel, and everything looks fine inside there. It's gotta be the coil...

[BA80]

Could be. Got a source you can get some to test with?

My experience with bad coils is once they dry out they work fine.

You might try swapping the coil connections and see if the problem moves.

Swap the power connections and the plug wires. Not difficult and easier than getting another set of coils to test with.

[ERM83]

Could be. Got a source you can get some to test with?

My experience with bad coils is once they dry out they work fine.

You might try swapping the coil connections and see if the problem moves.

Swap the power connections and the plug wires. Not difficult and easier than getting another set of coils to test with.

Greg...not sure what you mean by swapping. As in switching 1/4, 2/3 wires out?? (Meaning putting the wire that is on cylinder #1 on 4, and the same with the other coil)...

[BA80]

No, 1 coil fires 1 & 4 and the other fires 2 & 3. If the pug wires are long enough put the wires from 1 & 4 on 2 & 3 and vice versa. Then swap the signal wires to the coils so basically you are swapping coils from one set of cylinders to the other. If the problem moves to a different cylinder the you can be fairly sure you have a coil problem.

Seems like a lot of trouble but it really isn't

Are you CERTAIN it's just 1 cylinder misfiring?

[ERM83]

No, 1 coil fires 1 & 4 and the other fires 2 & 3. If the pug wires are long enough put the wires from 1 & 4 on 2 & 3 and vice versa. Then swap the signal wires to the coils so basically you are swapping coils from one set of cylinders to the other. If the problem moves to a different cylinder the you can be fairly sure you have a coil problem.

Seems like a lot of trouble but it really isn't

Are you CERTAIN it's just 1 cylinder misfiring?

yeah, without a doubt. not misfiring, just not firing AT ALL. I did the water spray test on the headers after warming it up, and #4 was cold...water just stayed on the pipe, while the others evaporated the stream IMMEDIATELY. gonna try what you suggested / pull the tank and check to see if i have a crack in the left coil. your advice is appreciated! I HAVE TO ride soon, or i'm gonna lose my mind, haha.