2004 Mastiff lost spark.

[moto-revad]

hi there, iv`e got a friends Mastiff 660 in the garage that lost sprk on a rainy day.

With everything dried out stripped and cleaned (and a new plug for luck) we get........NOTHING.

I have ignition live to the red/white wire on the coil, and cdi box (sidestand switch and kill switch working ok), and clean earth connections at the battery.
Continuity on all connections (checked with my AVO meter)
The engine turns over a treat and we have good compression, Just no spark.

Coil? Crank sensor? cdibox? What do you think?

Cheers, Dave R (revad)

[DAVID THOMPSON]

loose fitting spade lugs at the coil did me in one day on my traveller
they loose there grip when they get old
dave

[moto-revad]

Thanks for pointer. Have cut off and remade spade connections, cleaned coil spades and replaced HT lead. All looks like new.........Unfortunately still no spark.

I dont think the coil is getting the signal to fire from the cdi unit (up the black / yellow wire), and that is triggered by the crank sensor, yes?

Have engine cover off now and crank sensor LOOKS all ok, and have continuity to plug at cdi box.
How to check if its working though?

[den]

HAVE YOU CHECKED ,
IGNITION SWITCH?==where you put your key
SIDE STAND SWITCH,,microswitch by stand on frame
NEUTRAL SWITCH.little blue wire behide the front sprocket
handlebar kill switch,, wet corroded contacts inside,,bet yah

Theres a thread somewhere on the subject,, it lists all the safety circuits that stop a bike from starting

[Chalks]

I had a broken wire into the CDI that left me stranded at the roadside with my Baggy, it was running perfectly then died, no spark! I stripped and checked everything before I discovered it hours later. I ended up chopping out the multi-plug that joins the CDI unit and soldering on new terminals after my dear GF recovered me and the bike. OH WHAT FUN. (good luck)

[DAVID THOMPSON]

a good inspection where Chalks said is in order
on my rt125 the plug to the voltage reg from the wire harness died
(it just completely fell apart one night)
it was dry and brittle plastic and corroded wires
dave

[lance_brum]

Can some one please help me. I have a 2002 baghira and I am not getting any spark. I have check the neutral safety switch and fixed it, side stand switch is good, cleaned and replaced spade connections that needed it on the CDI box, electrical control, unit and the ignition coil. Still no spark. I have twelve volts coming from the cdi box on the red and white wire...so does that mean that my ignition coil is bad?

Any help would be greatly appreciated. This is my first project bike... I have the service manual, but my knowlege of electrical ignition systems is for sure limited.

Thanks,

Lance

[den]

tell us more , what happened ,, did you buy the bike with a fault?,did the bike work then go faulty,what,, what have you checked so far.have you checked the kill switch on the handlebars ??

[lance_brum]

I got given the bike....The previous owner said That it was running one day and he went out to ride it the next and it didn't start and that it just stayed in his garage for a few months after that because he had other bikes and didn't want to spend the time to figure out what was wrong with it. I did check the kill switch on the hand bars. It functions as it should from what I could tell...you turn it off and the starter won't turn over. Flip it to run and it will.

Since I posted,I found the resistance specifications for the ingnition coil in a service manual for the Baghira. So I tested it with the multimeter and it showed no resistance whatsoever in the primary circuit or the secondary. So, I have a feeling that will do the trick. I just wanted to seek wisdom of others before I spend a hundred bucks on a coil. Though, they said i could return it if it didn't work or "wasn't the right part."

Lance

[Bill Jurgenson]

FWIW:
I have never had. faulty DENSO coil.
I HAVE had several ignition boxes, however.
BTW, these are NOT CDIs = Capacitor Discharge Ignition.
The bike has a very normal battery ignition with HT coil.
Anyway, the blackbox does not have a particularly good reputation.
Of course, the wiring harness has a much worse one. The
idiot switches and the diodes hidden in the harness are possible/probable causes as are both (crummy) handlebar switches with their reputation of shortingto the bars.

[moto-revad]

FOUND IT!!

Tiny crack in the sealing resin on top of the Denso coil. Water getting in and creating havoc inside.

Swapped coil for a yamaha (denso again) that has rubber inserts at the LT connectors to prevent that issue and the jobs a goodun.

thanks for all your responses above, I have now a better insight to the Mz ignition system a s hole, so now much more clue d up as a result.

Cheers ALL.

[duncmac]

Happy you found it! Vrrom vroom!

[Srinath]

FWIW:
I have never had. faulty DENSO coil.
I HAVE had several ignition boxes, however.
BTW, these are NOT CDIs = Capacitor Discharge Ignition.
The bike has a very normal battery ignition with HT coil.
Anyway, the blackbox does not have a particularly good reputation.
Of course, the wiring harness has a much worse one. The
idiot switches and the diodes hidden in the harness are possible/probable causes as are both (crummy) handlebar switches with their reputation of shortingto the bars.

I believe I have a dead ignition box. No spark - now the goof up I did is this -

I had a bad ignition box before I think. I traced it to a bad transistor - it actually tested bad.
I replaced the transistor in the ignitor. I got it running but it always was hard to start after that. It acted up on startup almost right away ... I then took it for a nice long ride last october and it stalled on the way @ the off ramp when I let the revs drop, only to not start again.
Oh crap that sounds like the crank pickup trigger more than the ignitor box.

Let me check - that too - but have you had an ignition box open - and have you replaced the transistor (there is only 1 - 3 legged little square about the size of a thumbnail)

Now I have changed transistors on ignition boxes before, xs650, virago 535 ,1100 and others - see the pattern here - yes all yamaha ... and all of those have lived for several 1000's of miles to the extent I nearly forgot all about em.

Thanks.
Srinath.

[lance_brum]

Thanks for pointer. Have cut off and remade spade connections, cleaned coil spades and replaced HT lead. All looks like new.........Unfortunately still no spark.

I dont think the coil is getting the signal to fire from the cdi unit (up the black / yellow wire), and that is triggered by the crank sensor, yes?

Have engine cover off now and crank sensor LOOKS all ok, and have continuity to plug at cdi box.
How to check if its working though?

I have the same problem with my baghira... I have no spark. I have 12 volts from the cdi box to the ignition coil, and twelve volts in the spark plug boot, but no spark. I already replaced the ignition coil because there was something wrong with the circuits inside and it showed no resistance whatsoever. The new one is as it should be.

You said something about a crank sensor that is supposed to give signal to the ignition? Where is the crank sensor located? I have the service manual and I can't find anything about it in there. How do I know if it is good or not? Any other ideas? The main switch is good, I have already cut out harnesses and sauldered new connectors on the ignition black box, and on the coil. Check the other connections and fuses? I am at the end of my limited no how, and really like to get this bike going.

Any help is appreciated. Thanks,

Lance

[Chalks]

The sensor is located behind the alternator casing on the left hand side of the engine: