Bike wont start and strange spark

[Matt K]

I am starting a new thread because it appears the topic has changed. Here is the old thread that started this: http://www.thegsresources.com/_forum...ad.php?t=99536

And here is a update:
Ok yesterday I started my bike and let it idle for a few minuets. I then did a dumb thing and left the keys in it and in the on position. So I had a dead battery. I pulled the battery and charged it.

Today I put it back in. reconnected everything and tried to start the bike. No Go. The battery is just fine. The starter is spinning the engine with gusto. I can smell gas in the air box. But I don?t think I have spark. I pulled one plug wire and lay it on its side, and tried to start the engine. I did not see any spark. I also put an Allen wrench in the wire to cut the distance for the spark to jump. I did this on both 1 and 4 cylinder. I have never worked on a motorcycle and only have limited work on a car. I just don?t think I have spark and I don?t know what I did to make this happen. I did also check the fuses and all connections around the battery to make sure I did not accidentally disconnect one of them.
-----
When I started looking around at the wires there I noticed a VERY fired wire. It appears to be black with a white or yellow stripe. It goes up to the wiring harness that goes under a gas tank, and down to a box behind the rear break master cylinder. I removed the box.-----
OK today I got the module reinstalled today. I replaced the wire that was burned up in the wiring harness. I removed spark plug 4 and laid it down on the cylinder head. I then tried to start my poor bike. Well it did not start.

What I got was no spark, UNTIL I stopped pressing the start button. When I did that I noticed a very weak white spark. So I tried it again and got the same results.

So where do I go with this now? Should I start a new thread? Any help would be great!



I decided to start a new thread because it appears the problem has changed. Please help me out. I really don?t want to have to take my bike to a repair shop if I don?t have to.

Matt K

[chiphead]

Black with a white tracer was always the ground on the older suzukis.
Black with a yellow tracer was always the primary side of the ignition circuit on the older suzukis.
If that B/Y wire fried, you somehow got excess voltage/amperage through that circuit. May have cooked the CDI box.
Make sure all grounds are good and see if you can beg, borrow or steal a CDI unit and plug it in and see if you get the spark back.

[Matt K]

I am going to bid on a used one this week. should I also test the coils to make sure they are good? If so how do I do that? Or what else should I check?

[Guest]

Do you have or can you borrow a multimeter/ohm meter? You need one.
You should first check the spark on all 4 cylinders, not just one. If you have no spark on all 4, check the primary and secondary resistance on the coils. Primary (O/W to W and O/W to B/Y) should be 2-5 ohms. Secondary (plug cap to plug cap) should be 30,000-40,000.
Then check the signal generator (under the small cover on the right side of the engine) You should have a plug with 4 wires in it coming out of the unit. Check the ohms between Yellow/blue and black/green. Should be 100-300 ohms.
If the coils and sig. gen. check out, your ignitor (CDI) is fried, or you still have some burnt wires somewhere.

[Matt K]

ok I do have a multimeter. I will try to check that stuff tonight.

[Matt K]

First I wanted to thank you for your help. My resistance on the coil wires (O/W to W and O/W to B/Y) was 5ohms maybe a little bit more, because the meter was fluctuating a bit. The signal generator was about 260 so it should be ok. I do have a Chilton manual so it did have a way to test the CDI. connect a 1.5 volt batt to the blue and green wires. When you do this you will get a spark on one plug and when you disconnect it you will get a spark on another one. Well I tried that and no spark at all. So my CDI is DEA. I have won a bid on eBay for a replacement so I hope that is it. Thanks again for all the help!!!

Matt K

Do you have or can you borrow a multimeter/ohm meter? You need one.
You should first check the spark on all 4 cylinders, not just one. If you have no spark on all 4, check the primary and secondary resistance on the coils. Primary (O/W to W and O/W to B/Y) should be 2-5 ohms. Secondary (plug cap to plug cap) should be 30,000-40,000.
Then check the signal generator (under the small cover on the right side of the engine) You should have a plug with 4 wires in it coming out of the unit. Check the ohms between Yellow/blue and black/green. Should be 100-300 ohms.
If the coils and sig. gen. check out, your ignitor (CDI) is fried, or you still have some burnt wires somewhere.