Bike dead, no fire on Cyl 2 and 3

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This is not related to the coil because if i exchange the electrical cable from one coil to the other, the problem is moved to the other coil (Cyl 1 and 4). So there is no power comming to one coil....

I need help, where is the spark box located on this machine !!!.
 
Under the left side cover under the coolant bottle or fuse box,, careful,, remove the top screw of that cover!
 
zlMark said:
Under the left side cover under the coolant bottle or fuse box,, careful,, remove the top screw of that cover!
Click to expand...

Yeah thanks, this is the IC box, shouldnt be my problem since one coil is working.

My problem is probably the pickup coil. Have to remove the left side engine cover to find them both. Have bypassed the wire from both pickupcoil and found the defective one.

Is there a place online where i can order parts do you know ?
 
You can measure the ac voltage of the pickups coils at the disconnected connector while cranking, not sure how much it is but they both should be the same
 
If you find the pickup coil not generating ac voltage ( I would guess around 3-4v ac)then check the pickup coil air gap .5-.9mm

Pickup coil resistance is 390-590 Ω
 
zlMark said:
http://www.partsdepotstore.com/

So you switched the pickups around to fire the other half of the CDI and Coil?
Click to expand...


EUH..not really let me explain. I havent remove the engine side cover at all. I wanted to see from the connector comming from the Pickup coil under de seat. Since i have the shop manual here, it says that the bk\w and BL wire are comming from the pickup coil connecting Cyl 2 and Cyl3.
Knowing this, i unpluged the connector (under the seat) and took two 6inches electrical wire and crossed the connection vice versa.
The results, when i was using the BK and Y wire (comming from pickup coil for NO1 and No4 ), i was able to get sparks on Cyl1 and Cyl4 one time, and Cyl2 and Cyl3 the other time.
I did the same test but this time i was using the Bk\w wire with the BL one (comming from pickup coil for NO2 and No3 ). No sparks at all.

Before buying a new one, i will verify the air gap from the defective coil. This might cause it not to work if the gap is too much.
 
zlMark said:
If you find the pickup coil not generating ac voltage ( I would guess around 3-4v ac)then check the pickup coil air gap .5-.9mm

Pickup coil resistance is 390-590 Ω
Click to expand...


Thanks man for you help.

I have no tools to check that though. I can surely mesure the air gap. But, i dont see why the gap wouldnt be good... unless the bolts that is holding the pickup coil in place would be lose.
 
guess what, the gap was way off for the not working pickup, and was way too tight on the other one.

Problem solved. Nice blue sparks now !!

Will change the oil tomorrow (floaded with gas), and i will be good to go.

Thanks again for you help. This forum rocks !
 
Ok, i thought i had to lose the nuts holding the pickup coil to adjust the gap.... but seems you just need to pry with a screwdriver on the pickup to increase or decrrease the clearance.

Now that i have the bolts loose... they are so thin, i am afraid to break them because of tighting too much. At what torque do you guys think i should tight them.... should i use some lock tight ?
 
Re: Bike dead, no fire on Cycle 2 and 3

I would use loctight.No sense in risking a striped,or broken bolt.
 
Its funny that the range of acceptable gap down there is so big but they both have to be equal for the bike to run correctly>
 
I don't think the gaps have to be equal, just in spec. These are triggers only, the CDI is going to look for a minimum level to trigger, say 100 mV for laughs. One has 150 mV, the other side is 300 mV, it won't matter. The rise time to the 100 mV trigger level is almost the same, within 1/100 of a second or less. If one side doesn't meet the minimum level, then there's a problem. The CDI might even have a simple signal conditioning circuit built in to take two uneven signals and convert them into more stable signals, I don't know. Just my guess.
 
quoting the clymer manual page 263 pick up coil removal and installation line 6,b

"The pick up coil must be adjusted so that the air gaps (clearance between the timing rotor projection and the pickup coil core) of both coils are equal."
 
Maybe its my imagination, but when the gaps was not ajusted proprely, the spark from cyl 1 and 4 was there but was weak. Now the spark is big and blue on all the spark plugs. Still dont understand how the gap for Cyl 1 and 4 became near zero. The gap on the other pickup was way over the max tolerence.
 
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