yamaha xj600 no spark

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

hello just brought my first 4 pot project bike, is trying to start but no joy yet, looked at the ignition side of it and it has no spark on 1&4 and a very weak spark on 2&3, any ideas were to start , it has new plugs in it .

Freaky_1 · Nova Slayer Joined: 12 May 2010 Karma :

Remove ALL spark plugs so as to NOT crossfire.

Swap the electrical connections from one coil to the other (NOT the HT leads) and see if it's still the same two firing or if now it's the other two.

Though certain this part is obvious, if condition swaps to other cylinders, it's on the IGN side, if NO change in condition, bad coil.

Now swap them back before you forget and end up miss-wired once you get it firing. Laughing

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

cool i will try that, had another look today i put a test light on the 2 wires going to each coil, got a light on 2&3 coil but not 1&4 repeted this back at the cdi same thing could the cdi have had it ?, i also noticed the wires had new connecters on them, both coils have the same red/white wire and another wire each 1&4-orange, 2&3 gray.
also i have no neutral light ( its not in gear). thanks

J.M. · World Chat Champion Joined: 27 Mar 2011 Karma :

How old is the machine?

Mine had an issue with some of the connector blocks having corroded terminals. Increases resistance and makes some intermittent connections. I'd suggest trying the wires directly at the Ignitor Unit connector block and see whether they yield different results. (I.E. jam a multimeter in to the connector block whilst it's attached.)

https://oi45.tinypic.com/2jakdw4.jpg
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2004 R1 & 2018 XSR900

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

its a b reg so its a 84 bike ?,quite an old bike. yes i will clean all the connecters alot of the copper cable is black inside , just not sure why the neutral light wont come on and also have been told the rev needle should move while turning it over, there is no side stand switch its just taped off could this be a issue . thanks

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

have just tryed the wires to the coils right at the igniter box not sure how good my meter is as its only a cheap one , the wires for 2&3 coil is puting out 2/3v and nothing for 1&4, do the 2 wires from the pick up coil carry any volts i put the meter on the 2 wires going to the igniter and there was nothing also swaped the wires over on the coils and it switched nothing on 2&3 and weak spark on 1&4, any ideas. thanks

sidewinder · World Chat Champion Joined: 24 Aug 2011 Karma :

You have tried pulling the clutch in Very Happy

norbsa · L Plate Warrior Joined: 20 Jul 2013 Karma :

Hi,can anyone help with a problem with my 96 XF 650.The motor cuts out as soon as I engage a gear.I assume it's related to the stupid safety cut out but don't know where to start.Can I just by pass it?
Needless it's given no problems till now! Thanks.

sidewinder · World Chat Champion Joined: 24 Aug 2011 Karma :

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

yes i have the clutch pulled in , it looks like the side stand switch is missing , when turning over the oil light comes on no neutral light and rev guage does not move. i am thinking that it may be the igniter box or the pick up coil , both are not cheap parts, wanted to make sure it was not somthing little like a clutch/side stand switch or some wiring . thanks

J.M. · World Chat Champion Joined: 27 Mar 2011 Karma :

Theoretically you could short out the pick ups to test whether they function or not. They're just a basic switch. Also check the connector block for the pick ups.

The side stand switch shouldn't matter too much. Basically it will earth a 12v feed to the ignitor unit. If the device is missing then it can't earth it. If the devices is faulty then it could.

The clutch switch isn't important. However if missing the wires need to be joined together otherwise there is a break in the circuit and nothing will happen. I don't remember off heart (and haven't checked the diagram) but I think that switch only interferes with the starter motor, not the coils.

Unsure how the neutral switch/light functions on this bike entirely. However the neutral switch will earth the 12v feed to the ignitor unit if it thinks the bike is not in neutral. This could be one thing happening; a faulty switch earthing the live feed mostly.

I'd be testing everything with a multimeter first before buying anything. Start at the battery on the wiring diagram and figure out the circuit the electricity takes when powering your coils. Then test everywhere on this circuit, starting from the battery, to see where the power drops. That'll leave you with your answer.
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2004 R1 & 2018 XSR900

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

right time for a update i was 80% sure the cdi was bad, so i slid the cover off hoping it was not sealed in, and it wasnt , and sure enough a component had burnt out, turned out to be a triac could not find a new one with the part number on it so i went down to my local maplin and got a triac to try, solderd it in and no joy Sad

still no spark on 1&4 but 2&3 wires know has power to it all the time, when testing with a test light , so no idea what i have done, looks like i will be buying a cdi of ebay, the only thing is i cant find one for a 84 bike , i see one for a 86 bike the numbers on it are nearly the same on my one it says tld14-78 3km-00 brown label and the 86 one tld14-78 3km-01 blue label , does any one know if it will fit ,same amount of pins, but not sure . thanks

numberofthebe... · L Plate Warrior Joined: 19 Jul 2013 Karma :

also the is the diagram on this topic for a 84 bike, the reason i ask is the plug with the pick up wires that go into the cdi i only have the 2 wires for the pick up ,but on the diagram there is a yellow/black wire that goes to the clocks , my bike does not have it.