April 18, 200521 yr It could be a bad ignition part, but I would first check if it's a sheared flywheel key. The change in timing caused by the rotor moving would account for the backfiring. You'll need something hold the flywheel with for R&R of the nut, a torque wrench for replacing the nut and a flywheel puller. Flywheel holding tools are pretty easily made from a flat bar and a couple bolts that match the holes in the flywheel. Male sure the bolts don't go too far through. and damage the stator.
April 19, 200521 yr Sorry, didn't mean to hijack, added onto this one as it was the same issue? My problem is I aint got a clue about ignitions, flywheel keys, what they look like or even where they are??!?!? Think I'm gonna have to take it to ERJ's in Stockport
April 19, 200521 yr My problem is I aint got a clue about ignitions, flywheel keys, what they look like or even where they are??!?!? I sure ain't no mechanical expert, but having spent many (un)happy hours fiddling with my Rev-3's ingition in an attempt to solve a persistent engine knock, I can point you in the right direction: Remove the right-side engine cover. You're now looking at the flywheel. To remove the flywheel you'll need a puller - these can be purchased from a dealer or alternatively, make your own as detailed by CharlieC elsewhere in this thread. Once you've got the flywheel off, look closely at the shaft on which it was installed. There's a slot with a small piece of metal sitting in it that locates in a corresponding slot in the flywheel. That's the key and it's fairly common for them to break, causing problems very similar to those described in this thread.
April 19, 200521 yr Fantastic, cheers fella, I'll have a look at that, next door neighbour used to fix my old Fantic 240 & Majesty so I imagine he'll have a puller.
April 20, 200521 yr Author Got bike started @ weekend, but made the fatal mistake of stopping it then it would not start again. So if anyone has any more ideas i'd be really grateful
April 21, 200521 yr There's obviously something wrong with it. Just because it started doesn't mean you're any closer to fixing it. You have to shut it off sometime! How did it run? Did you do anything to try to fix/diagnose it?
April 21, 200521 yr Author Tried the plug cap thing as suggested in an earlier post. It was not keen to start, but then ran OK, until I turned it off. Have not had time to look at it again this week.
April 23, 200521 yr I've got a Rev 3 (01) and my mate has an '02, and at the same trial, both of our bikes packed up and wouldn't start. Both had a weak spark. Turned out to be the CDI unit. Cost about
April 25, 200521 yr Job snorted, turned out to be a faulty plug on mine, purrin like a pussycat again now
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