Electrical problems - no spark - SOLVED

[Beelzeboss]

Hi everyone,

as the title suggests my engine has no spark. I've tested pretty well every wire for continuity, kill switch is shorted closed, clutch switch is shorted closed, side stand switch is shorted closed, so it's not anything there.
The bike cranks and sounds very healthy but there is absolutely no spark. The coils both have +12V at the positive terminals but nothing at the other terminal. I've tested both coils and they have the correct resistance values in the primary and secondary windings. The chassis and engine are both grounded well, so... I'm out of idea's except for a broken CDI/ignitor unit.

Since a new one has been quoted as $999.17 AUD I'm looking for a slightly cheaper option.

From reading the desription on this kit (from Jaycar, similar to Radio Shack in the US), do you think it will work? In the book catalogue it says it will work with 1-4 cylinder engines...
http://www.jaycar.com.au/productView.asp?ID=KC5466&CATID=25&form=CAT&SUBCATID=347

Also are there any other things I should check on the wiring harness? I'm having the CDI tested tomorrow morning.

Cheers,
Andrew

[Dr.Sparkie]

im going to go ahead and say that if you COULD make that box work, you would need two.. one for each igniter-coil combo. it doesnt look like it has enough wires to even work with two igniteers, two coils, power and ground.

that being said, I have no idea about the performace specs, but if you can solder (you must assemble the components yourself) and you like to tinker im sure it would work... provided the box isnt crap.

might be better to get a used ignition module, or at least borrow one from a close-by rider to make sure yours is in fact knackered.

[The Buddha]

Its a known trick to put in a ford duraspark ignition or a gm's ignition in the thing. Yes you need 2 ... and there is a CX650 that someone did that way, virago's, maxim 650's etc etc have all had these done. Google it, if you get nothign, post here, I'll find it.

I am attempting this on my virago ... but that has vacuum advance in addition to the regular inductive. If I can bypass that, heck I'll wire in the GS one.
Anyway, on a 89-00 GS the ford/gm pne should work, cos it got no vacuum advance.
Cool.
Buddha.

[The Buddha]

And I just had the thing load up ...

It actually looks like it could work and be easier and cheaper than the ford. Ask him if its a true CDI or is it a TCI. Sometimes we tend to use them interchangeably, and they really are different.
Cool.
Buddha.

[Beelzeboss]

Cheers everyone, but I had the CDI tested and it checked out fine. They tested it in one of their bikes and it ran.

So, now I think its the signal/pulse generator. The Haynes manual I have (only up to 1999) says there should be 250-420 Ohms resistance across the signal generator, but all I have is an open circuit on all wires... I'm guessing it's broken, however in the manual it shows two of the little black sensor box things, whereas mine has just one of the sensors. Is this normal for a 2007?

Do I have to replace the signal generator? A new one is $270 so I'll be looking around the wreckers.

Thanks,
Andrew

[Beelzeboss]

Does anyone have Haynes manual for a 2007 GS-500? If so, could you possibly find out if the signal/pulse generator is meant to be open circuit, or what resistance it's meant to have?

Cheers,
Andrew

[Beelzeboss]

Problem solved, was the pulse generator. $100 later and the engine fired into life.

Don't ever put straight pipes on your bike, it is the LOUDEST thing EVER! My ears were ringing for ages after I gave it a little rev (no tacho, could have been to 6,000 rpm or so)

Cheers,
Andrew