My bike recently (three of the last five rides) started "cutting out" and "running rough" after anywhere from 20 minutes to one hour of riding. Sometimes setting the choke will keep the bike running, but it still runs rough. If I let off of the throttle, the bike usually dies, and usually won't even jump (roll) start. If I cut if off and wait about two to five minutes it often will crank and run fine.

It has done this twice in dry weather, and once (the worst time) in the rain (and I mean a downpour). When it died in the rain, after a minute of two, I could crank it and go about 100 feet before it would die again. The third time it died, I pulled the seat and disconnected and reconnected every electrical connection under the seat. After that it cranked and ran about 400 feet then died. I waited about one minute and cranked it again, it then ran fine for the next 100 miles. The next day it ran fine for the entire ride (about 80 miles).

Two years ago I replaced the fuse box with blade type fuse receptacles with caps, soldered the wires and used heat shrink wrap and black tape to seal the connections.

Any clues as to what I need to check and how to go about it? I have a volt ohm meter and I'm not afraid to use it. ;)

Thanks in advance.

May sound wierd but that same problem happened to me with my kickstand safety switch. The symptoms you are mentioning are the same that I experienced. I removed the switch on my bike and wired it direct and that fixed the problem. If your bike has that safety switch it is worth checking

i would have to agree, im not to fond of having cut off switchs all over my bike. Their nice at time but a pain to trace to,thats why i only have two.

Thanks for the kick stand safety switch idea. I'll check it out.

If the problem gets solved, I'll report back what all I did.