Date: 09-05-24  Time: 09:33 am

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Messages - doingitdeeper

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1
Hi there

I've just dismantled the relay. It's basically two bog standard relays, three diodes and two resistors. All fine.  I had carried out the tests detailed in the Haynes manual, the most of which are continuity between certain pins. It failed a lot of them where it's "out your probes this way, you should see resistance. If you reverse the probes and get anything other than open circuit it's broke".

However it does it's job by supplying the correct 12v and the relays work too. Testing the diodes and resistors on the board revealed they were doing what they were supposed to be doing.

Relay:
https://ibb.co/XybG1t5

There was a wire off on the barrel when I got the bike, so I had to drill the security bolts out and resolder it. Barrel all fine.

Yes neutral light, it cranks, everything else works. As above all cutout switches work and are correct

I've ordered another CDI box today and on the hunt for a pickup coil but they aren't easy to find. That's about all I have left.

If I wave a screwdriver across the pickup coil whilst cranking it doesn't fire. The resistance only drops from 206ohms to 180ish too. It looks clean and fine but I suspect that's the issue

2
Thanks I'll give that manual a go tomorrow. I don't fancy putting it through my scope in case it decides to fire and fries it haha

With me having two cdi units and neither work I'm inclined to believe it's between the pickup sensor and the relay, if it indeed does more than supply 12v to the CDI unit. There's a few diodes in there I think are passing current where they shouldn't. I'm going to disassemble it tomorrow and test the diodes and resistors inside too.

Thanks, will update.

3
Hello, thanks for the reply.

Yes both terminals on the low tension side of the coils are getting 12v.

It appears everything is well except for the cdi unit discharging it's capacitors. To me, all that points to is either the pickup coil (could be wrong, I can't find anyone else's readings anywhere for a working one) or the cdi unit itself.

When spinning the starter the voltages at the low tension side never stray from 12v on the wires coming from the cdi unit.

However as I have two, the previous owner bought a new one to try and rectify the fault, I kind of saw it as a little unlikely. But never say never!

Does the main relay simply provide 12v to the CDI unit and that's it?

4
Hello. Long time lurker and hoping that theres still enough people on this board to help me out. I always prefer forums as it is, but here goes..


99 fzs600 with no spark. I have absolutely ran out of ideas why. I bought it with no spark, the previous owner gave up.


I have:
  • two igniter boxes
  • new plugs
  • new leads
  • new coils
  • tested pickup coil - 260ohms
  • loop plugs x2 in place under the seat
  • replacement loom, all continuity tested, all plugs clean
  • anything that would kill the spark has been tested and proven to work (kickstand, clutch switch, cutout switch)
  • every wire going into the igniter box has been continuity tested to where it ends up, via the haynes mnaual
  • new battery


I have 12v at the back of the coils with ignition on.


clean earth points.


absolutely stumped but i have three really important questions:


  • The two white plugs under the seat with looped connections - one of the plugs has four connections, but only two are looped. Is this correct?
  • Is there a way to bypass the ignition cutoff relay in order to rule it out? It HAS failed some of the tests in the haynes manual but from reading the diagrams it seems to just send 12v to the igniter box anyway, which it does.
  • Pickup coil reads 206ohms and jumps to 260ohms when ignition is on. When it picks up a signal from the rotor, it only moves around about +_20ohms. Is this correct?


As you can see i am knee deep in this thing at the moment and am stumped how something so simple can refuse to work.


The bike is mostly in bits as a winter project and as such i have great access to everything.


Thankyou in advance for any replies!

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