2004 Gas Gas 250 MC Cutting out.

[eff]

Well if you have cleaned it all out and it is still doing it, then I guess you will need to look on the electrical side as referenced above. I can't help you with testing the coil. Good luck.

The needle has the number stamped on it and you should write that down too. You will need all that info if you plan to tweak your jetting in the future. What needle you have will will require different main and pilot jets.

[lonetree]

my 04 ec did exacly this....
i cleaned, re cleaned and re cleaned the carb again , nothing, no change.
change 3 plugs, nothing, took air cleaner off, nothing. on and on this went, had spark and everything,
started fine, but no mid to top end, sounded like the exhust bung was in it or somthing.....
finally, i checked the ignition lead, where they connect onto the coil, it seems to be just a push on type connector, it had come off just a little, pushed it good and hard, bike has run fine since....
have a look there first.... good luck

[GMP]

Its NOT a push on connection. The coil has a recessed stud terminal like a wood screw, and threads into the HV lead wire. The sealing fails over time and lets water in. You need to remove the wire and cut it back about 10mm, clean the coil/stud as best as possible. Use some Honda grip glue as an adhesive sealant on the HV wire insulation and small boot, and thread the wire back on the coil. Check the plug cap also.

[Nekocopter]

Thanks a ton for all the help guys, gonna work on it a bit tomorrow and see what I can do.

Will post back results tomorrow, and some pictures of the ol' girl

[Nekocopter]

Well, she's still cutting out.

Cut a little off the plug wire, cleaned the post on the coil, reassembled, still having the same issue .

Anywhere else I should start looking before I break down and bring it to a shop?

I'm hoping it isn't CDI related.

[jhendr3702]

for grins... i would lean the clip on the needle and see if it is any better..
my 01 has run beautifully for 3 years, but with the climate here this year, i had to change and it is fine now..
easy and cheap..

[GMP]

Put a timing light on the HV wire and see if the misfire correlates with what you see.

[MJC]

Have you checked the reeds ? When they are chipped or cracked it will cause the bike to sputter on the topend as you are describing alot of times.

I also had a bike that I pinched the coil wire on. I pinched it between the frame and the radiator in a fall ,and it didn't look that damaged , but it was and it caused the bike to run like crap as the rpms went up. What a nightmare that was to diagnose.

[Silver]

sounds like yet another cdi but no one ever listens chase your tail . Listen to them tell you its this its that . Good luck . Been there done it twice both times cdi. I hope its something simple as cdi's are not cheap.

[bossmans kid]

Did you clean your power valve? make sure it is not sticking, also check your reeds. Just a thought.