Lowlife, Thanks! I still wanted to know how to attach a photo to my post so you could see the wire harness I was asking about. I could not find the info in HELP. Dan

 

I have that special tool! Its made by Matco and you plug an air hose into it! LOL! To post pics Dan, you have to upload your pics to Flicker or a free hosting site like it. Then you will have a url to copy and post on your message. Oh and dont worry about the starter gear clearance. What lowlife said is right.

 

Hey Guys! I got my new starter and recoil I ordered. I installed the starter, connected the wire. I wanted to see if the pinion was turning, so I installed that, the CVT cover, the grd wire, the CDI, and the battery. All I get is a clicking inside the magneto cover. Everything worked before the recoil came apart. What in the heck is going on now. I thought the battery was dead but it reads 12.47 volts.
I'm ready to take an axe to this thing. HELP? Is there something that I need to do when I remove and reinstall the battery OR the CDI?

 

Lowlife, I got my new starter and recoil I ordered. I installed the starter, connected the wire. I wanted to see if the pinion was turning, so I installed that, the CVT cover, the grd wire, the CDI, and the battery. All I get is a clicking inside the magneto cover. Everything worked before the recoil came apart. What in the heck is going on now. I thought the battery was dead but it reads 12.47 volts.
I'm ready to take an axe to this thing. HELP? Is there something that I need to do when I remove and reinstall the battery OR the CDI? When you remove and replace the CDI does it need to recharge or build up the voltage before it starts?
Same question of the battery? Is there somewhere on the internet that shows the service manuals?

 

sounds like you might have a bad or dirty connection

 

Connections are spotless. Unless there is something in the Magneto cover I need to check? I'm not sure if the magneto even comes into play before it's running does it?

 

It isn't that unusual to have a bad starter. Even though it's new it can still be bad. I would check there. Remove the starter from the bike and see if you can get it to work on it's own. If it checks out ok, then when you reinstall it double check all your connections and make sure none of the gears bind when the starter is activated. The CDI and battery are plug and play. Sounds like the battery is holding the correct charge so you can rule that out. The CDI has no special parts on it, like I said plug and play. However, I have heard of people burning out their CDI due to improper install. When connecting and disconnecting a battery some recommend that the positive wire be the first diconnected and the last reconnected. I've never had any issues but it has happened in the past to other people. If you know someone with a good CDI, see if they will let you use it to verify a potential issue. Otherwise you may need to purchase a new one. If the latter is the case DO NOT buy a factory one. Purchase the Dynatek CDI with the Rev limit switch option. You'll be upgrading that part sooner or later so you might as well get the right one. If your CDI is good then it's a simple process of checking and rechecking connections, continuity and that nothing binds. Good luck. Let us know what you find.

 

Hey Dan6995, I was at my buddies house today helping him with his water lines and was able to take a look at the wiring on the LTZ50. I was wrong about the black/white wire. That wire is hot going to the coil along with a solid black wire to the spark plug. The black/orange wire you mentioned it open. It doesn't connect to anything. It may be an accessory wire that just isn't used. I didn't get to see if it has a voltage or not but if it does, it would be an easy wiring job to add a driving light. Just a thought.

 

Lowlife: Still didn't get it started. Makes no sense.
Another subject, Trying to put it back together. In the transmission case(1) : I installed, on the shaft, 1. washer (16), 2. Damper plate (9), 3. spacer-long (3)
4. Face-movable (w/rollers) (2), belt (24), face -fixed (sprocket) (1), washer (14) and nut (13). Then I have the starter cup and recoil from recoil starter page. What holds the starter cup (otems 2&3)on the shaft? I don't see anything in the parts list. I installed these according to the Suzuki parts list. Can you look at the parts list for the transmission? It also makes no sense there is a gasket for the CVT cover and none for the recoil cover. Why wouldn't that get water in there?

 

Lowlife: I know of no one with an LTZ50. As I said, is there something in the magneto box that should be clicking when I try the starter? When I installed the CDI the key was out and off. There's nothing binding. There is no power to the starter at all. Can I put 12Volts directly to the starter when I have it out?
I hate to oder a new CDI and find it's not the problem. I will purchase the Dynatek but not until I know this thing will start. I'm ready to burn it!