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Discussion Starter · #1 ·
I bought this 97 Tex from my boss a little over a month ago. Did all the basics cleaned carb, oil change, new battery, new solenoid, ran fine for a week then lost spark. I replaced the coil no luck, replaced the regulator no luck, replaced the cdi no luck, replaced the pulse gen.... got spark back. Go to put it all back together and start it up then bam fuel issue. Cleaned the carb again put it back in. Would run really rough and the die out. Messed with it a week and found that my carb has two jets one low and one high and my low jet didn't get cleaned good enough cause I couldn't see though it at all couldn't get it clean so I boiled it in water to be able to get a needle though and break the gunk up that worked so I went to try it out again almost certain this was the issue. Now I don't have spark again.....: it's like my pulse generator is out again. I have the wiring schematics but don't know what to make of them regarding this issue. The pulse generator wasn't just replaced so I don't think it's the issue. What causes them to go out? The stator should be fine cause I've never even tried to start it without it hooked up to a running car or a battery charger up on 12v boost.
 

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gonna go with a short some where in the wire harness.
 

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Discussion Starter · #3 ·
My pulse regulator cracked, I just put this in last week. What would cause it to crack? I've been trying to start it a lot lately but if it's supposed to handle normal operation and that's constant rotations.
 

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My pulse regulator cracked, I just put this in last week. What would cause it to crack? I've been trying to start it a lot lately but if it's supposed to handle normal operation and that's constant rotations.
is the flywheel running true ?, any chance the woodruff key is sheared , and the flywheel is hitting the pulse generator ?.
 

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is that a Chinese replacement pulse generator?

if so, I would just attribute that to bad quality control. start over, no fun having to do a job twice due to inferior parts.
 

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is that a Chinese replacement pulse generator?

if so, I would just attribute that to bad quality control. start over, no fun having to do a job twice due to inferior parts.
if you look really close at the pick up ?, it looks like it has a hit mark on the side ?, or no ?. that's why I was wondering if the part on the flywheel may have hit it. and broke it ?.
 

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How can I check that? I still have it apart waiting on the new IPG to come in. What exactly would I be looking for?
look on the flywheel, raised metal part, see if there is any marks on it from it hitting the pick up ?.
 

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Discussion Starter · #10 ·
Not that I see, and I don't see where the woodruff key is located? Is it farther in? I've only ever went this far before.... is the stator supposed to turn freely at all? I couldn't get it to budge.
 

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Not that I see, and I don't see where the woodruff key is located? Is it farther in? I've only ever went this far before.... is the stator supposed to turn freely at all? I couldn't get it to budge.
only the flywheel turns, the stator NEVER TURNS !..LOL. the woodruff key is wedged in between the center of the flywheel groove and the crank's groove. you won't see this until you pop the flywheel off. if the woodruff key is sheared ?, then this would let the flywheel '' free '' spin on the crank, and you don't want that to happen !..lol.
 

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also, the flywheel is pressed onto the crank, and this key keeps it from turning.
 
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