GP1200 Keeps Blowing Stator, No Spark.

[gvsu141]

Hi, I recently picked up a highly modified 1997 GP1200. I had to hook up a few things when I bought it - exhaust, cooling lines, starter, etc...

It started and idled/revved fine on the trailer. When I took it out to test, the first time accelerating past idle the engine died before it even got on plane. I found out the charging coil went bad in the stator, with open resistance between the black/red and brown wires. After replacing this coil, it once again stared fine. On the next water test, accelerated hard to about 50mph, then immediately died again. I tested the charging coil and once again found open resistance, this time on all circuits of the coil.

Does anybody have any idea on what could be causing this to blow? I don't see any shorts, bad grounds, etc. From what I can tell everything looks to be wired correctly, but no guarantees. It has a RIVA Quick Rev CDI model RY11818 made in November 1998.

Mod List:
145+ PSI in all 3 cylinders
RIVA CDI
.020 over with WISECO pistons
Milled Stock Head (RIVA head included, but not installed)
Ported Cases
A.F.M.S Carbs (Similar to SRE)
RIVA Intake
Exahust work
V-Force Reeds
Pro-Tec ride plate and grate
RIVA extended nozzle
WORX Spontons
Ball Bearing Steering and Handlebars
Aluminum Clutch & Throttle Levers
Custom Paint
Primer Kit
Aftermarket Mats
Aluminum Fuel Cap
Solas Impeller
12 Vein Stainless Pump Stator

[Cutlass]

Are you using quality stators/charge coil replacements? Maybe that CDI is bad and burning out the coil.
NICE looking GP by the way!!

[gvsu141]

NICE looking GP by the way!!

Thanks!! Now only if I can get her going decent - haven't had a chance to really ride it yet

[gvsu141]

Are you using quality stators/charge coil replacements?

The coil that I replaced it with was a used stock one that I had as a spare. I'm trying to find a deal on another one - all the ones online seem to be pretty expensive.

[gvsu141]

Maybe that CDI is bad and burning out the coil.

That's what I'm fearing - can a bad CDI cause this? Any way to test other than swapping for a stock one? I hear that a stock CDI is a recipe for disaster with a higher compression engine.

Could a bad flywheel somehow cause an issue with the stator?

[Cutlass]

Sounds like you're using oem quality parts, so thats good. I've never heard of a CDI burning out a charge coil but I'd think its certainly possible. If I understand the system, the charge coil charges up a capacitor in the CDI and the CDI waits for the pulser coil to trigger it to discharge to the ignition coil. So if there is something wrong with the capacitor, it could burnout the charge coil. do you have a GP1200 service manual? there are a bunch of ignition system and CDI tests you can do to see if something is out of spec.

[gvsu141]

That makes sense, if a capacitor is bad it could send all that back to the charge coil. The pulser coil tests within spec.

I have a manual, and it has a large 12x12 with different resistance values for the stock CDI. I guess that I could try to do the same tests with the RIVA unit, and see if the values are close (if the wires are the same).

[gvsu141]

While taking off the 2nd stator, I think I may have found the issue. This time, I noticed that the flywheel was actually loose, and could be wobbled by hand. The flywheel bolt backed out. This caused the flywheel to rub against the main coil on the charging coil, rubbing a small scrape in it. There was the same, but smaller scrape on the first that I didn't notice before.

I tightened it by hand, but need to buy/make a tool to hold the flywheel in place to tighten to the 50lb.

[gvsu141]

Picture of the first coil:


Picture of the 2nd coil:

[Cutlass]

Good find! I think I used a block of wood to jamb up the flywheel and keep it from spinning while tightening. Can't remember for sure if that worked or I did something else