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Discussion Starter #1
Hi Gents,

I've been on this site for the past 4 days trying to get this rev limiter problem nailed. Some people say cut the green with white stripe and ground it......
ground which end?

then others say....just cut it......dont ground it......
then other say, buy the product from ripper blah blah......off of ebay.

So I cut the wire, stripped both ends, added an extra length of wire and then ran that to a ground on the bike. took off the parking brake cause I read that that will also trip the limiter.

ALL THE RESULTS ARE THE SAME

After starting each time I tried a fix.....the rev light stays off until the bike starts to warm up....then as I try to slow give is gas......
I DIES.......OR WANTS TO......

ITS NOT UNTIL I REALLY GIVE IS SOME HARD THROTTLE THAT IT WILL REV UP AND STAY RUNNING.......of course pissing off my neighbors each day at the same time........

thoughts???
re-direction........
carbs are clean with new jets but I had the problem before the new jets anyway........

I'M EVEN TIRED ABOUT READING THIS PROBLEM UP HERE......
ALMOST TIME TO THROW THE TOWEL IN FOR A SUZUKI OF KAWI 450 AND BE DONNE WITH IT

HELP!!!!!!
 

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Re: Same REV LIMITER ?? again. Correct solution.

Green/white wire by the shifter is the reverse switch.

Cutting and grounding it, the wire, not adding a wire to the plug sticking out the motor, will keep the cdi from knowing it's in reverse.

The flashing reverse light is a rev limiter for neutral I believe, I had a problem with my reverse light flickering while I rode and just cleaning the connection and slightly crimping the plug on the end of the green/white wire fixed it. I didn't have to ground mine, didn't want to give up the dummy light.

The second wire by the shifter is neutral, try unpluging it if your just reving it in the garage, fool the cdi into thinking it's in gear. See if the reverse light still blinks.
 

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Discussion Starter #3
Re: Same REV LIMITER ?? again. Correct solution.

OK, so I got the reverse light to stay off....you were right......I couldnt believe the dirt and crap on that little plug....
THE PROBLEM IS.......

its not running any better......it still wants to die with the slightest bit of throttle (hickup and slight backfire)

the only time it runs ok is when its cold and the choke is on.......
WOW....I must be on crack or something.......just typing that makes it sound like a whole other problem right??
 

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Re: Same REV LIMITER ?? again. Correct solution.

Agreed, different problem.
Ever had your choke out of your carb?
Year of machine?
Mods?
I'm not that great at carb problems.
 

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Discussion Starter #5
Re: Same REV LIMITER ?? again. Correct solution.

never had the choke out.....wouldnt know where to begin....although I did find the posted pdf file/manual...I guess I could use that.

2004 660
K&N airfilter
HFM SLip on
150/155 jets
only ride in sand at Glamis
+2 A arms and +4 axle

the motor is stock

is there a can of something I can put in the gas tank to clean the gunk in the lines.....
should I take of the carbs and clean them......
any suggestion would be helpful......I had this problem at seasons end last year and its making me crazy.......

I like the adrenaline......Im no master mechanic

thanks for your help

Mike
 

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Discussion Starter #7
It is a GREAT write up with pics. Believe it or not, I used this when I put the new jets in with the pipe thinking that would solve my problem.....it didn't.
But, I think I will be doing this again this weekend with some serious cleaner and go thru those carbs.....they have to be gunked up somewhere.

Thanks for your help
I'll let you know the outcome.....
 

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Discussion Starter #9
NEVER A STUPID QUESTION......
I did replace the spark plug but not the coil wire..........
I came home today and after cleaning the carbs and spraying them down with cleaner etc.......
I started it up and after reving the engine for several minutes and having it pop and sputter....it eventually ran much much better.......I just wonder if something wasnt gunked up, or something in the fuel line.
I experienced this in the middle of last season......and had to deal with it on and off.
I wonder if it was bad gas or something?

thanks for your help....
 
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