Cylinder/head studs on Suzi T20

[doug rooney]

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[Suzukidave]

I am really not trying to sound mean ... but .. i feel it would be best to sort all the bodgered wiring before trying to figure out why it will not run right

[jabcb]

Since you are have having trouble with the left side but the right side is good, you can do a simple test to eliminate some of the potential problems.

For the 2 temporary white-to-white & black-to-black wire connections you have at the stator, switch them out. Using additional short wires, connect left points/condenser to black wire & right points/condenser to white wire.

Repeat your tests with this setup. Does the left side still work correctly? Do you now have problems with both?

If you are going to try to run the bike with this setup, make sure to switch the spark plug leads too.

[doug rooney]

No offense taken dave. I know it's a jumbled mess from trying everything I can think of with the wires. Have done what you say before jacb BUT, I "don't think" I switched the condensor wires??? Would make a huge diff! Will give it a try. Thanks

[jabcb]

For the test:
1) if you still have trouble with the left side but the right side is good, then its the points and/or condenser
2) if it switches and you have trouble with the right side but the left is good, then its the coil, ignition lead, plug cap and/or wiring
3) if you have trouble with both sides, then you likely have multiple problems

[doug rooney]

Did as you suggested jabcb and stayed the same. RIGHT side hot, left throwing gas! I don't get it. Still messing with it. BTW: I DID switch the condensor wires in the past when I tried this. After looking at it, even I couldn't be THAT dumb! LOL!

[jabcb]

Just to make sure we are on the same page.
Wired correctly, you get good spark on right side & problem with spark on left.
Wired with points/condensers switched left with right, you get good spark on right & problem with spark on left.

Did you check the coil primary & secondary resistance?

[doug rooney]

Spark "appears" (Have those plug connectors that are transparent and can see the spark. Tried it with them off and same deal) to be good on both sides no matter which way I switch things around BUT as of now, it is still firing nicely on the right and just gas coming out on the left no matter how I switch them around. Not sure how to test coil resistance?? People have told me before but probably didn't do it right. If you explain it, please....Kindergarten simple. Thanks jab

[jabcb]

Is the left plug getting wet? Could you have a fuel/carb problem on the left cylinder?

[doug rooney]

AHA! Fired it up this morning at about 4am in the dark shop. While running, it suddenly switched to the left working and not the right and I could see a "short" spark BEHIND the stator/generator! 90% sure I've isolated the problem. Would say 99% but have said that before to no avail. LOL! I'm PUMPED! Stay tuned and thanks for all the input guys! Will take that off later (which I've done many times) and try to figger out where it's coming from.

[doug rooney]

Glad I didn't say 99%!! GRRRR! Took the stator/gen off and took it apart. Crumbling insulation and bare wires exposed to the inside of the thing. Carefully taped those up TWICE on 2 different ones and same deal. Left side good now and not right. I do belive it almost HAS to be grounding out in there (saw it this morning). I'm 8% "sure" that's the prob....LOL! Maybe get a different stator???

[doug rooney]

Fired it up this morning again in the dark and cannot see a ground out spark like yesterday BUT, still doing the same only the left is firing well and spark is weak on the right at the points (intermittent). Can someone walk me through a coil test? Thanks

[jabcb]

There is a T20 website with some info: http://www.t20suzuki.com/
Click on "T20 Data" for some specs.
They also provide a wiring diagram: http://www.t20suzuki.com/wiring.htm

Took a look at eBay to see what your coils look like & found this:
http://www.ebay.com/itm/SUZUKI-X6-T20-H ... 0709795159

Coil primary resistance should be about 2 ohms.
Check resistance between both orange wires & white wire -- should get infinite & about 2 ohms.
Check resistance between both orange wires & black wire -- should get infinite & about 2 ohms.

Coil secondary resistance should be around 5k to 10k ohms.
Check resistance between spark plug cap and white or black wire, depending on which coil you are checking.
The plug caps might also have 5k resistors -- in that case the total resistance should be 10k to 15k ohms.

If the coils are ok, then its also useful to check voltage drops. Use something thin like a metal paper clip that you can insert into the coil connectors to get voltages with everything hooked up & the ignition on. All tests are for voltage between ground or battery negative terminal. Check:
1) battery positive terminal
2) coil orange wire connections with points open & closed
3) coil black & white wire connections with points open & closed
4) battery positive terminal (to see if the voltage dropped during your tests)

Since the left side is working ok, you have a reference for looking at the ride side.
Let us know what you get. Its easier to explain your results than to list all the possible outcomes.

[doug rooney]

OK jab, Did precisely as directed. I have 3 sets of old coils (6 total). Before I proceed any further, this is what I find: ALL test the same. Have 4 ohms on the primary. My voltmeter when set to "ohms" shows a 1 all the time. It's lowest setting is 200 ohms. When testing as per your instructions, it does NOTHING but stay on that initial "1". Doesn't fluctuate....nothing. Tell ya anything? Thanks

[jabcb]

If the meter is showing a "1" when set to ohms & the leads are not in contact with anything, then a reading of "1" indicates infinite resistance.

I was expecting a resistance of around 2 ohms for the T20 coils. The coils in the T250/T350/T500 have a resistance of around 4 ohms. But maybe Suzuki used 4 ohms coils on some T20s.

The secondary side should be at least 5k ohms, or at least 5,000 ohms. To check this you will have to adjust the meter range setting.

Your meter might not have enough precision to distinguish between a good & bad coils. Could you provide a pic of your meter.