Aeolus 300 Losing Power - CDI or Ignition Coil?

[bhof53]

My 7-week-old 2008 Aeolus 300 just turned over 1,000 miles today, and celebrated by acting up! On the way into work, I could feel the engine cut out for about 2 seconds on 2 different occasions. It came back quickly, and I made it to work with no issues.

On the way home, it got worse. Had to pull over 3 times before continuing on. The first one was just for about 30 seconds. The second and third stops were 2-3 minutes each.

Both times the scooter had been ridden for approximately 20 minutes before it acted up. When I stopped on the way home, the lights, gauges, and fan still worked, but it just wouldn't turn over. After sitting briefly, it started up and ran for a short distance before starting to cut out intermittently.

Based on those symptoms, is it the CDI or the ignition coil? In reading here, it sounds like the CDI would just go out completely, and this is more likely to be the coil, but I wanted to check with folks more knowledgeable than me!

After feeling the power drop on the way to work, I quickly ordered a new CDI and coil both from Scrappy Dog, but the CDI is backordered for a week. So hopefully it is just the coil instead!

And now the dumb question that I haven't really found an answer to: Where is the coil located if I need to change it? I know the CDI is under the right foot panel, but I don't know where the ignition coil is at.

Thanks,

Brent

[wile]

Find your Spark Plug on your motor the coil wire that goes on the Spark plug follow that back to usually a round cylinder that is your coil.
Wile

[torque]

If it sputters at higher speeds after a few miles of riding, check your vacuum hoses and fuel pump.

Mine developed a problem where it would run for a few miles, then sputter a time or two, and then die. After sitting for a few minutes it would restart.

The problem resembled some cdi behavior, but was in fact a small hole in a vacuum line right where it attached to the fuel pump.

[bhof53]

Thanks, guys! If I would have waited to get the coil in my hand before asking, it would have been immediately obvious where it went!

I'm leaning toward either the CDI or coil, because by the time I limped it home, it was doing it at most every speed, and wasn't consistently at higher speeds. And it had been ridden close to 20 miles before it started acting up both times, too, but I will definitely keep the vacuum line in mind!

I'm doing the 1,000 mile switcheroo to synthetic today and will swap the coil and then take it out on a close-to-home loop and beat on it for 45 minutes or so to try and make it fail. If it does, I guess I'll wait for the CDI, but hopefully this will fix it. If it does, I'll order another coil and keep it and the CDI under the seat with my toolkit to avoid getting stuck somewhere!

Brent

[torque]

I doubt it's the coil. Could be, but not a common failure point on this bike. CDI, fuel pump, and vacuum lines more likely to fail; based upon what I've seen here on this forum over the past 4 years.

Good luck.

[bhof53]

You're right, it wasn't the coil. Took it out for a ride and it acted up again in less than 10 miles. Let it cool a bit and it got me a mile closer to home, before giving up completely. Would turn over but run very rough for a few seconds before dying. Guess I'll wait for the CDI to show up and then try it again.

Brent

[torque]

You know -- it's just a hunch, but I'm guessing it may have to do with the fuel supply. Too low a float level in the carb, hole in a vacuum line to the fuel pump, or possibly the fuel pump.

Your statement about it "running rough" for a few seconds makes me suspicious. Just doesn't sound like a typical cdi failure on this machine. Go ahead and swap it out, since u already have one coming, but if that's not it -- I'd bet on one of the above.

[bhof53]

Got distracted for a few weeks, and finally had a chance to get back to this. You're right Torque, it wasn't the CDI. My next step is to replace the fuel and vacuum lines.

Tore the clutch apart the other day and cleaned it out good and roughed up the clutch pads. Wow, what a difference that made! Takes off like a rocket and the throttle response is instant. Hasn't ridden that good in any of the time that I've had it. Or at least it rides wonderfully for 10 minutes or so, until it dies!

OK, back to the dumb questions now. I'm not overly mechanical, and none of the local shops in my small town deal with off-brand bikes, so I'm kind of on my own for any repairs.

First dumb question: where are the vacuum and fuel lines located? I've got everything tore apart pretty good, but I don't know what I'm looking for! Lots of other posts mention about replacing fuel and vacuum lines, but I couldn't find any that discuss actually how to do it. Any input would be greatly appreciated (and pictures are even better!).

Second dumb question: Once I know where the lines are, where can I get replacements? Are they a standard size that's carried by normal auto parts stores, or will they need ordered somewhere? I'm sure I could get them from Sunright, but local is better (and faster!).

There are a number of threads lately about an Aeolus running for a while and then dying when it gets warmed up, but there's rarely a followup to tell what actually fixed it. When I get this resolved, I'll be sure and come back and update this thread with the solution.

OK, enough dumb questions for today!

Thanks,

Brent

[torque]

You may not have to replace them. And I doubt it would be a fuel line. If that were the case, you'd see fuel leaking somewhere. Most likely any break would occur either at the point of attachment to the fuel pump or the manifold; or else at a point where it's rubbing against something. You might just be able to trim off a piece if the break is at one end or the other.

At any rate, I would think an auto parts, or motorcycle shop would have it. Just take a sample in for them to match. Don't tell 'em what brand bike you're working on. (btw I'm no mechanical genius either -- just things I've picked up around this forum.)

[richardthescooter1]

Vacuum line are located under your seat area, if your gas tank is located in behind your seat, you will have to remove the seat and plastic to get too them. you can get vacuum line at your local auto store.

[bhof53]

Thanks for the info. I still have to ask another dumb question: what do the vacuum lines connect to? There are a lot of hoses under there!

Brent

[bhof53]

I found a PDF version of a Yamaha Majesty 250 service manual, and looked into that this evening. Tore the seat off so I could see better what's going on. Following the diagrams in the manual, I found which is the vacuum line. Pulled it off and discovered a crack right above the clamp where it comes off the fuel pump. Or at least I hope that crack was already there, and I didn't cause it when I was twisting off the hose!

Anyway, $1.37 of hose later from Autozone, I re-installed it, and put the scooter mostly back together.

Then as I put everything back together, I noticed the coolant reservoir was a bit low. Filled that up, and it started leaking! Pulled that off, and discovered there was a leak at the seam of the tank. Cleaned the antifreeze off of that, and got some silicon sealer applied.

Anyway, in the morning, I'll take it out for a run before work to see if I can make it fail. If that $1.37 hose was all it took, I'll be a happy camper!

Brent

[raha111]

keep us posted Brent, my 300 does the same thing once in awhile but has never died completly. it just sputters at high speed sometimes then picks back up and runs fine.

[bhof53]

Bummer! The scooter behaved exactly as before with the new vacuum line on it. Guess it's time to move to replacing the fuel pump?

Hey, the good news is I now know where it's at! Every time I tear more of this scooter apart, the more knowledge I soak up about it, so this isn't entirely bad. Mostly bad, but not entirely bad!

Brent

[bhof53]

An update on this. Tore the scooter apart further, replacing the fuel lines, fuel pump, and fuel filter. Blew into the new fuel line into the tank, and there didn't seem to be any obstruction in the pipe going into the tank. Started it up, and could see the gas flow nicely into the new fuel filter. Have now replaced everything between the gas tank and the carb.

Let the scooter run in the garage for about 20 minutes. Revved it a lot to simulate driving. Ran like a champ. No sign of stuttering or problems.

Put everything back together and took it out today, and it conked out in about a mile. Each trip where it's died has been getting progressively shorter. Went from about 5 miles to 3 to 2 to about 1 today. So whatever it is, it's getting worse.

Spent some quality time in the country watching some horses along the road for about 20 minutes, and then was able to drive it back home. Luckily it conked out on a big hill, so I was able to coast back down about a quarter mile before having to start it up.

I'm at my wit's end with this piece of crap. I don't even know what to try next, other than Craig's List! I told my wife if some sucker was standing there with $500 in cash, they could have walked away with it today. And they would have had to walk away with it, because it was running pretty rough by the time I got it back home!

The only other idea I have is maybe a bum spark plug. I had replaced the plug right after delivery with an iridium plug, so I guess for another $9 I can try that. Advanced Auto ordered me one before, so I guess I'll pay them a visit today to order another one to try tomorrow.

Any other ideas?

Brent

[cloudsifter]

Would it be worth running some Berryman's or Sea Foam, or other 'clearner' type additive through the tank?

I hate to see a fellow new owner having problems with their Aeolus 300. I've had mine about 3 months now and have hit about 1400 miles and am having a blast.

[torque]

DEFINITELY run some Sea Foam thru it. Really helps starting and performance.

a) Is the float level high enough?

b) R u sure there are no vacuum leaks?

c) Does your replacement fuel pump deliver enough flow?

d) have we talked about valve adjustment already? This can affect vacuum level to the fuel pump. Mine were fine at 6000 miles, but this certainly sounds like some kind of fuel starvation.

[torque]

You're in OHIO! --- Just caught that!

I know that Jackson, Ohio is a bit of a drive for you, but they sell the Linhai 300! That's where I bought mine. So if all else fails -- contact them: www.hondasuzukiofjackson.com/

Ask for Mike in service. Tell him Tim from Studio E Music sent you. They know these machines!

Also -- Jim as Sunright is a great resource. -- Service manuals, tech advice. Very easy to talk to.

[richardthescooter1]

Two things come to mind. First, you couild have a bad ignition coil. I had the same problem in hot wheather, turned out to ne a bad coil. Another thing it could be is your intake clamps are loose, at higher speeds any vacuum leak your going to shut down until you regain your vacuum.

[torque]

didn't u replace the coil already?

[richardthescooter1]

Sorry, he already ordered one.

[bhof53]

Yes, I replaced the ignition coil initially with no effect. When it was running rough, I tried to plug in a new CDI, and that didn't affect it either.

The vacuum line has been replaced with new line, so I don't think it's a vacuum issue.

I'm going to try the new plug today and see about adjusting the carb float. Does it need to be set higher or lower? Torque mentioned to set it higher, but it seems like it should be set lower, so it thinks it needs to pull more gas to the carb sooner. Or am I thinking about it wrong?

I'll pick up some Sea Foam when I get the plug today, and will try that out.

Here's the replacement pump I installed. If it's specifically called "High Flow" it shouldn't have a problem with not pumping enough gas!: www.scootertronics.com/mihiflfupufo.html

Since the scooter is behaving the same as before all the parts I've swapped, it's got to be something else.

Thanks,

Brent

[torque]

That looks like the right pump. If the engine is "starving", set the float level higher. If it's flooding, set it lower.

[leo]

Jul 12, 2012 20:40:20 GMT -5 bhof53 said:

Based on those symptoms, is it the CDI or the ignition coil?

based on the symptoms i would say you have a connector problem.
coils and CDIs just outright fail, they don't go "half bad" or "sometimes work".

In reading here, it sounds like the CDI would just go out completely, and this is more likely to be the coil, but I wanted to check with folks more knowledgeable than me!

a bad coil will either not fire at all or give such a weak spark that the scoot will not start.

And now the dumb question that I haven't really found an answer to: Where is the coil located if I need to change it?

follow the plug wire, it goes straight to the coil.