TW cuts out, dies, starts and runs fine...repeat
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  1. #1
    Senior Member kj7687's Avatar
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    Ok so, I've been having a problem with my TW for quite some time now. It will fire up and purr like a kitten, run fine without any problems for a few minutes (this time seems to be shorter now than it used to be when I first experienced the problem), then just sputter out and die, sort of like it were running out of gas. Sometimes it will start right back up, or it will fire a little but won't start, then it will usually start after sitting there dicking around for a couple/a few/several minutes. I've thoroughly cleaned out and inspected the carburetor, twice; it is perfect in there. I've also replaced the ignition coil with a brand new one, and replaced the CDI box with an ebay unit. I'm wondering if perhaps the CDI I bought on ebay is also faulty, and perhaps a NEW CDI would fix this problem? Any help/suggestions appreciated.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  2. #2
    Senior Member RodneyReed's Avatar
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    Make sure your tank is flowing gas freely though the petcock. Maybe some trash has got it clogged up. Also, maybe your tank is not venting. Try running with the gas cap loose.

  3. #3
    Senior Member lizrdbrth's Avatar
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    By chance did you ditch the fart can, or remove the tank to service anything recently??



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  5. #4
    Senior Member kj7687's Avatar
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    Quote Originally Posted by Rodney View Post
    Make sure your tank is flowing gas freely though the petcock. Maybe some trash has got it clogged up. Also, maybe your tank is not venting. Try running with the gas cap loose.


    I have checked and cleaned the petcock, clean as a whistle...I have also tried running it with the gas cap off. Same deal. Thanks.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  6. #5
    Senior Member kj7687's Avatar
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    Quote Originally Posted by lizrdbrth View Post
    By chance did you ditch the fart can, or remove the tank to service anything recently??


    Fart can? lol? Charcoal canister? It's on there.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  7. #6
    Senior Member demarko69's Avatar
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    CDI,mine had the same symptoms, put on a cdi, runs great

  8. #7
    Senior Member kj7687's Avatar
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    Quote Originally Posted by demarko69 View Post
    CDI,mine had the same symptoms, put on a cdi, runs great


    I thought that might well be the problem. Installed a "new" one from ebay which did not fix it. It's possible however that the one I bought was having the same problems (maybe the guy who sold it was a jackass and knew it didn't work...). I'm thinking it's possible the rectifier could be responsible.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

  9. #8
    Member RTCarroll84's Avatar
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    CDIs are an expensive part, before buying ANOTHER one, test anything else it can be. Look up the shop manual on the forum and run down the list progressively. If you looked through the electrical section you'd see the the testing for the CDI is to test everything electrical before it, and if none of that is faulty THEN replace the CDI.



    Could still be fuel related, check your float bowl level, and make sure u still have plenty of gas in the bowl while the engine is running. Also check vent lines. When you start up are you starting on the choke? and have you tried it without the choke aswell?

  10. #9
    Junior Member Tferre's Avatar
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    This may sound stupid, but maybe its the octane of your fuel. I put premium in mine and had the same problem as your describing. I emptied the tank filled up with 87 octane. Took a minute to burn out the old fuel, but once it got the lower octane it ran great. Just a thought
    Welcome to Utah, the State of Adventure!

  11. #10
    Senior Member kj7687's Avatar
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    I've already checked the vent system, and been inside the carb, twice just to make damn sure. It's all perfect in there. Not using choke other than when it would normally be necessary. I'll dive back into the manual and go through all the electrical crap as soon as I get a chance. Thanks. As far as the octane level: I've run 91 before without any trouble. However, I'm sure I have 87 in it now. Thanks.
    KJ, just KJ, ok.


    Current rides:
    2004 GMC Sierra 1500, 1999 Toyota 4Runner

    Past rides: 2015 Yamaha XT 250, 1997 Suzuki DR 200, 2007 Honda Ruckus, 2007 Yamaha TW 200, 2007 Kawasaki Ninja 500, 2009 Kawasaki KLX331S; 1994 GMC Sierra 1500, 1987 Nissan Pathfinder, 1992 Acura Integra, 1986 Honda CRX, 1989 Jeep Cherokee, 1994 Chevrolet Astro Van, 1979 Volkswagen Rabbit, 1984 Jeep Cherokee

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