I have a 2001 GS500. I am getting no spark on either side. My battery is good. Both ignition coils are new. What is the next thing I test? Is there somewhere that has like a troubleshooting checklist for this?
There are no less than 3 switches on the GS500 that can inhibit spark. They are circled in red in the image below.
1. Ignition switch
2. Engine stop (kill) switch
3. Side stand switch (when in gear)
The clutch switch is also worth noting, because it will prevent the starter from turning if it is not pulled in. (also circled red)
The signal generator inside the right hand engine cover (circled in blue) is also worth checking. And of course, if the Igniter is faulty, that means no spark either.
(https://i.imgur.com/U6ZxgiR.png)
if it cranks, but no spark and after new ignition coils and i bet u changed sparks too, check the CDI (this thing controls when the sparks should ignite), there was a fuse somewhere, i don't know what it does, but check it to be sure its alright, if the cdi works, next step is cables
Quote from: nikolai_01 on November 16, 2020, 05:02:47 PM
... there was a fuse somewhere, i don't know what it does, but check it to be sure its alright.
If it cranks, the fuse is intact. Power for everything is supplied through the fuse, including the starter switch on the handlebar.
Yes. If the fuse is bad. The bike does nothing at all. I replaced the fuse. When I turn the key on as far as I know everything that should happen. Happens. I thought with the 3 switches that were listed that the bike would not even turn over if either 3 of them were tripped? Yes when I replaced the spark plugs with the ngk that are recommended. And then I replaced the ignition coils. There is also a relay that I checked and opens/closes with voltage applied. That you very much for the schematic. Right now I don't have the spark plug boots on. I have about 1/4 inch of bare copper showing and I still have no spark at all. I'm assuming what I need to do is work my way backwards starting with the spark plugs?
In order for us to try and help you troubleshoot your problem, please provide some background info. Did the engine run at all? When? What have you done prior to it not wanting to run? Does it crank? What is the battery voltage?
Sorry. I was trying to include all the information that I could think of.
The bike did run. It has been at least 10 months since it has started. I didn't own the bike at the time, but I have seen it run.
The battery voltage was 13.3 the last time I checked it. The battery is only 3 months old.
What I have done so far is I just replaced the battery, 30a fuse, spark plugs and the ignition coils.
I have also taken the boots off the spark plug wires so I just have bare copper wire.
I'm looking for basically what to test next and after that. Like a troubleshooting check list. Like, spark at the plug? Yes no. Yes you do this. No you do this. Or something like that I guess.
I am an hvac service technician by trade. So I have a multimeter and I have a pretty good knowledge about testing electrical components. I have just never worked on any kind of motorcycle electrical system before in my life. I was just hoping I could get some help so I didn't have to literally
Only thing I could think of is cdi module, I've seen a few bikes with 'broken' cdi units, it's in the tail, under the rear fairing, left or right side
I'm not aware of a step-by-step guide on ignition problems on the GS500. It may be out there, but I'm not aware of one. Once you get your bike sorted out, maybe you want to do a write-up and post it on GSTwins.
Have you tested the 3 switches that I pointed out to you? Feedback on that will be appreciated. If the switches are fine, the CDI would be the next thing to check, or have checked, or swapped out with one that you know works. Suzuki calls it an "igniter".
There are many videos on YouTube for testing CDI's and ignition problems on motorcycles. This one is a good start (pun intended): https://www.youtube.com/watch?v=jaSKU2m3qbI (https://www.youtube.com/watch?v=jaSKU2m3qbI)
And if you feel really stressed by the non starting bike, watching this video is guaranteed to put the smile back on your face:
https://www.youtube.com/watch?v=0ZR0FX1_icg (https://www.youtube.com/watch?v=0ZR0FX1_icg)
The 3 switches that you listed. No I have not checked them. I was under the impression that all 3 of them switches will stop the bike from turning over at all. My bike turns over trying to start. So I just assumed that the 3 switches were good. Is this wrong? Can the bike still turn over but no spark if one of these switches is open? If so I will absolutely check them as soon as I get home.
Now that you mention it... I'm not sure if the engine will crank with the 3 switches in the off position. I can't check for you, because my bike is partly disassembled.
Maybe someone else with a running bike can test.
Those switches would prevent the bike from turning at all, so if the bike cranks but doesn't start, the switches are fine, check cables and cdi, SK racing shared a video on how to check the cdi and I bet that it's the problem. I think they aren't expensive, like around 30$
Edit: my bike will start only when the switches are fine and in correct position, tested 2 months ago, because clutch switch went out(kinda)
Thanks for confirming, Nikolai. I couldn't remember. :thumb:
Quote from: Ferriest86 on November 17, 2020, 01:12:34 AM
I'm looking for basically what to test next and after that. Like a troubleshooting check list. Like, spark at the plug? Yes no. Yes you do this. No you do this. Or something like that I guess.
Here you go...Happy troubleshooting :2guns:
(https://iili.io/FYj7gs.md.jpg) (https://freeimage.host/i/FYj7gs)
(https://iili.io/FYj51n.md.jpg) (https://freeimage.host/i/FYj51n)
(https://iili.io/FYjadG.md.jpg) (https://freeimage.host/i/FYjadG)
(https://iili.io/FYjc7f.md.jpg) (https://freeimage.host/i/FYjc7f)
(https://iili.io/FYjle4.md.jpg) (https://freeimage.host/i/FYjle4)
(https://iili.io/FYj0ml.md.jpg) (https://freeimage.host/i/FYj0ml)
Wow, Sporty. Who would've thought to look in the Service Manual? That's cheating! :hithead:
Well done. :cheers:
Sporty thank you very much for the pages. Is that from a repair manual or something?
Nikolai what do you mean when you say to test the wires? What wires are you saying for me to test?
Yea lol. Service manual. Duh. I just don't know enough to know I'm missing things. My first go at a motorcycle. I'll figure it out eventually. I didn't know that service manuals were like that with the troubleshooting and pictures and everything. I guess I'm going to look into a manual for the bike.
Quote from: Ferriest86 on November 17, 2020, 11:07:47 PM
Nikolai what do you mean when you say to test the wires? What wires are you saying for me to test?
What I meant is first to check the spark plugs wires (don't know how they are called), but you told us already that you have put a bare copper. Next thing is check all cables coming from the tail up to the front, there was a guy with similar problem somewhere in a local facebook group with different bike, but similar problem, he found the problem and it was a 'cut' wire (the isolation was good, but wire itself was cut inside from twisting)
Hey Ferriest86 what year is the bike?
I think the diagram shown might be for a newer one coil system; the older style had 2 coils and 2 pickups on the signal generator.
I never seen anyone test the spark without having the plug boots on and the sparkplug leaning against the head (as per video.)
Try it that way, as its much easier to see your spark, and the spark gap will be close to proper range.
Also did you replace the coils with stock? I'm new to these bikes, but in general I've heard that you can mess up your CDI
if you change to a coil with different (less) resistance.
Quote from: chris900f on November 18, 2020, 07:49:14 PM
Hey Ferriest86 what year is the bike?
I think the diagram shown might be for a newer one coil system; the older style had 2 coils and 2 pickups on the signal generator.
The thread title says 2001 model.
Good catch on the wiring diagram. Earlier I posted the newer 2004 diagram with 1 pickup. According to the service manual, 1997 to 2002 models shared the same two pickup diagram. Thus we can assume the change to one pickup came in 2003. All models have two coils, though.
Below is the correct diagram, showing two pickups.
(https://i.imgur.com/wj28Mxr.png)
The bike is a 2001. The cdi is bad. Wasn't doing anything at all. I just bought a used one on eBay for $25. Hopefully there isn't anything else. Lol. Thanks for all the help. It is very much appreciated.
Great, good for you for finding the problem. Well done! :cheers:
The information that I got from everyone that responded helped me a ton. And just being able to say something about it. I troubleshoot heaters and air conditioners for a living. The thing is I know how they work. Or at least how they are supposed to work. The motorcycle thing Is totally new for me. I need to get a service/repair manual for the bike. I didn't realize that they had troubleshooting guides and things like that in them. What is the preferred service/repair manual for a 2001 gs500?
I sent you a PM yesterday.
Well I haven't been able to catch the flight I've been so busy. I finally got out there last night I was messing around. the 3 wire plug that goes to the igniter when I text her resistance between BR - b/bl and G/W - B/BL. Manual says it supposed to be between 350 and 420 home on each. The G/W reads in range but the other reads OL. So what is that a broken wire or something?