January 15, 201411 yr Author New chain and sprockets on now. I was a bit surprise I had to adjust the rear wheel to the 5th marker to get the chain at the correct slack. Still wont start, but I think it is unrelated to the chain going. She was getting awkward to start anyway. I've checked all wires are in place, adjusted the timing chain, checked fuel is getting through etc. I do have spark at the plug, but appears quite weak and yellow. Mrs Elvis has had to go to work so I'll pick up another plug tomorrow. Fingers crossed that will sort things.
January 15, 201411 yr Moderator A yellow spark isn't good. Big, fat and blue one is very good. Keep us up to date.
January 15, 201411 yr Author Will do! The plug is about 6k miles and 12 months old. If I hadn't been ill over New Years none of this would have happened!
January 15, 201411 yr Moderator Check the HT lead connections at the coil end and the cap end too and any coil earth. Pour a spoonful of fuel down the plug hole, replace the plug and see what happens.
January 15, 201411 yr Moderator you've been asked this before ...did the incident lock the engine...a very sudden stop?
January 15, 201411 yr Author Didnt lock the back wheel up, by the time I had pulled over onto the hard shoulder I had already hit the engine stop so honestly don't know for sure.
January 15, 201411 yr Author Most of the chain had rolled off but the last few inches were stuck behind the drive sprocket casing.
January 15, 201411 yr Moderator if there's any chance the chain stopped the engine turning suddenly (which it seems likely) then maybe you should check the flywhhel woodruf key hasnt sheared. If it has, this could be a reason for a poor spark
January 15, 201411 yr Author Forgive my ignorance but is the flywheel behind this: If this is it, do I need to remove the casing, or should I be able to see by removing fig 1 and 2? My torch is beginning to fail now so I'm struggling to see anything!
January 15, 201411 yr Moderator you'd have to remove the casing and also have the correct tools to remove the flywheel Andew, cant be too specific...i'm not familiar
January 15, 201411 yr Moderator Yes Andrew but you need to take the whole case off, not just a cover. The flywheel should not spin independently of the crank (or piston). The flywheel needs to come off to change the woodruf key. Great suggestion from Paul BTW.
January 15, 201411 yr Moderator Page 4-44 in the manual is a good place to start and look at the diagram on 4-46. If it is the woodruf key it should be able to be fixed with the engine still in the frame and no changes to the timing.
January 15, 201411 yr Author Cheers for that. I can get a finger in and I cannot turn the flywheel so I'm hoping that means the woodruff key is good. I'll get the casing off tomorrow and check properly.
January 15, 201411 yr Remove the casing, use a puller and the woodruff key will be sitting in a slot on the crank (if its still there). I asked if the burst chain had stalled the engine, which if it was wrapped round the engine sprocket, it would have done then there may be some damage to the valves of may have knocked the ignition timing out. If as you say it was becoming a crap starter with a poor spark could indicate an ignition cdi fault. They usually just fail, but my sons old sr125 went through 3 cdis during his ownership (problem being buying from a breakers meant replacing a 20yr old part with another 20yr old part)and one of those displayed a weak yellow spark. Unfortunately the only testing method is by replacement
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