Not getting spark. Now what?

[fyarl666]

There are ignitor tests shown in the service manual as Rusty says.

Anyone have a .pdf version? Finding stuff like that locally is more of a challenge than finding out what's wrong with the bike.

I have a suzuki manual, but it's really just basic spec stuff and schematics, it doesn't really explain how to do voltage tests and whatnot.

[rustybronco]

Bikecliff's site....

http://members.dslextreme.com/users/bikecliff/

[fyarl666]

Okay, I got the damn thing trucked back to my house finally, thanks to the help of several friends.

Gonna start by checking the coil after I get the tank off.

If those are good, should I be tracking down a new ignitor box?

[tkent02]

What did the diagnostic testing you did say?

[fyarl666]

What did the diagnostic testing you did say?

Wasn't able to do any testing yet. It's been a rainy week here and as soon as I had all the tools outside to take the tank off, the sky opened up again I didn't think it was a good idea to have all the electrical exposed to all that rain so I cleverer everything up and came back inside.

I'm just trying to think ahead a few steps. I'm thinking it's either the coils or the CDI box that is the culprit.

[tkent02]

It's not the CDI box.

[fyarl666]

It's not the CDI box.

Wait, is the CDI box the same as the ignitor box? Or is that something different?

[tkent02]

An ignitor box is what Suzuki uses. A CDI is what Kawasaki uses. An entirely different type of ignition system.

[fyarl666]

An ignitor box is what Suzuki uses.

Okay, so it still might be the ignitor box that is guilty.

[fyarl666]

Okay, Ive been quickly trying to compile a list of test data in between cloud bursts, and here is what I got so far (keep in mind THE BIKE WON'T START, so I did all the tests I could think to do with a dead engine.)

Battery at Start: 13.3 volts.
I then did a quick key start to double check that indeed the spark plugs weren't sparking, and the battery dropped to 12.6 volts.


Left side coil:
Ohms @ 200: 3.7 primary,
ohms @20K: 1 secondary.

The service guide I got from Bike Cliff's site indicates that the primary should be 3.5 - 4.5, and the secondary should be 23 - 25,

right side coil:
ohms @ 200: 3.8 primary
ohms @ 20k: 0 secondary

service guide states primary should be 3 - 5 primary, and 21 - 25 secondary.

So that's bad.

Next, I did a diode test on the new RR.

1. Red Lead to red wire, Black Lead to all the yellow wires, all three readings just said 1.

2. Black Lead to red wire, Red Lead to all the yellow wires, 508, 505, and 507.

3. Black Lead to Ground wire, and Red Lead to all yellow wires: all three said 1.

4. Red Lead to Ground wire and Black Lead to all yellow wires: 515, 498, 464.



New stator test, Ohms @ 200, between all three yellow wires: .8, .9 and .9.

Between all three yellow wires and touching the engine case, it just stayed
at 1.

After all this, checked the battery again, 12.7 volts.

So there, everything I could get at the time.

Obviously the secondary for both coils are bad, but what could cause both coils to go bad all at once?

Any other tests I should be doing (keeping in mind the bike doesn't run)?

[posplayr]

Did you measure 12v at the coil (+) ????
Also the coil(-) shoul go up and down as you crank the engine over .

[fyarl666]

Did you measure 12v at the coil (+) ????
Also the coil(-) shoul go up and down as you crank the engine over .

No, I didnt measure 12v at the coil. And I might need a few more sets of hands in order to hold the mulitimeter leads and crank the engine at the same time. Ill report back tomorrow.

[posplayr]

No, I didnt measure 12v at the coil. And I might need a few more sets of hands in order to hold the mulitimeter leads and crank the engine at the same time. Ill report back tomorrow.

Alligator clips

Strip wire wrap around the probe


Hold between knees

[fyarl666]

Alligator clips

Strip wire wrap around the probe


Hold between knees

Where exactly should I be touching the multimeter leads?

[fyarl666]

And are you using the range scale correctly? K ohms for the secondary? Should be 2 - 5 ohms, on K ohms scale it will read zero.

I'll do it again tomorrow, try to change the range.