My 2005 200 runs backward!!!!

[td04h]

I've installed a new stator coil AGAIN!!!

Now it doesn't want to start, kicks back alot and when it does start it is in reverse.

I have advanced and retarded the timming to the max, but it has the same problem!!!

Please help!!!!

 

[Throttlem]

Sounds like you have sheared a key on the crank where the flywheel fits. Simple fix.

 

[KIWI KDX]

yep you have done a woodruf key!

 

[td04h]

no, that's what i can't understand. The key is fine and installed properly to line up with the flywheel.

 

[domino dave]

I had a key one time that was part way sheared. Looking at it,with the flywheel on,everything appeared ok, but in fact the flywheel had moved just enough to cause huge problems.Have you taken it apart for inspection since the problem started? If thats not your case, I'd like to hear from someone that has other idea how to help you ... Can you do wheelies in reverse?(just kidding) Dave

 

[Tom68]

Sounds like you need to start from scratch and check all connectors and component spec's, kicking back is too much advance, not familiar with the 200 but my 250 ign pickup is external and separate to power windings.

 

[reepicheep]

Running backwards? The crank must be in upside down. Or maybe you should remove the wheels, turn them upside down, and reinstall. Or maybe you are kicking it over forward instead of backwards.

(Just kidding :) )

I guess if you were playing with the timing and replacing the stator, you must have had that stator cup off, so you would have seen a sheared key... unless you sheared it on the last install.

Was there any debris on the rotor magnets from the previous failures? And just thinking out loud, I wonder how the bike detects the crank position? Hall effect sensor? Magnetic switch? Waveform from stator? On my Buell it's a hall effect sensor, and it doesn't seem like the stator output would be a reliable trigger. But it must be something on that stator, because that's what you turn to change the timing...

 

[td04h]

the key is fine. i removed the flywheel and removed the key. installed the flywheel again, but turned it 180 deg. same problem. turned the flywheel 90deg back and starts on first kick the right way round. So my timing with the key installed is 90deg to fast?


Any ideas???

 

[reepicheep]

Is it an OEM stator assembly? Or aftermarket? Got the part number handy?

Oh, and how the heck did you get the flywheel on in anything but the correct position with the key in there?

 

[td04h]

i took the key out before installing the flywheel 180 and 90 deg. its not an oem stator. it burnt out about 5 times. got it rewound. maby the problem is there?

 

[reepicheep]

Thats what I would look at next. I don't know how Kawasaki senses the position of the crank, but you change the timing by moving that stator around, so it must be off something on that assembly, probably triggering off of something on the magnet bell housing (though it could be off the crank itself somehow)...

I'm sure somebody here knows how it actually works... my service manual is at home so I can't look it up here.

 

[Tom68]

If it triggers off the stator and the ign circuit differentiates between rising or falling voltage the stator must be connected backwards.

 

[sr5bidder]

wow thats all I can say

 

[glad2ride]

What is the last thing you changed? That is the problem.

 

[reepicheep]

Hey, that's a clever approach from Kawasaki. I wonder how they kept it from getting fussy with temperature and RPM (which would change the amplitude of the voltage). I wonder what the actual schematic is.

 

[tedkxkdx]

http://www.dirtrider.net/forums3/showthread.php?t=88332&highlight=bike+running+reverse
check this thread out. It is the same issue. The stator.
I don't think I mention that running in reverse made my reeds explode and then get sucked back in the cylinder. Gee, I had to replace my piston because of this. So check your reed cage prior to restarting for forward motion.