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Enduro Electrical & Wiring Lighting, Ignition, Wiring, Plugs, etc.


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  #1  
Old 04-04-2016, 03:40 PM
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Default 2006 EC200 ignition fault diagnosis

2k3 ignition and the plug sparks when the engine is turned. Strange fault cut the last ride short. I'm 90% sure it's an ignition fault - the bike became increasingly hard to start, then would just about run at low rpm whilst cutting in and out every few seconds.

What little I know about ignition is mostly from youtube Could someone more knowledgeable check my results are in the right ballpark:

Pulse Coil (red-green wires) 97.2 ohms (manual=100 ohms)
Exciter Coil (black/red - red/white) 14.4 ohms (manual=12.7 ohms)
B8EGV (no resistor) spark plug - cap end to tip 0 ohm, cap end to threads 0 ohm (same result when heated)
HT lead and plug cap - visual inspect - insulation in good condition, plug cap to end ht lead= 4.5 k ohms, check continuity whilst flexing ht lead=same result
Coil, centre core to tab= 0 ohm, centre core to ht lead 'screw'= 0 ohm

Under the ignition cover, everything is clean and dry. I pulled the flywheel and stator plate to check, all looking good. The main bearing seal is also clean and dry. Maybe worth checking the carb, reeds and p.v., but would be suprised to find any problems there.

I guess I could double check the continuity of the wires to the cdi (multipin) plug. Other than that, the cdi would need sending away for testing.

Any ideas on anything else to look for?


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Old 04-04-2016, 04:31 PM
pigpen966 pigpen966 is offline
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Look at the coil to spark plug wire connection.
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Old 04-04-2016, 04:31 PM
Neil E. Neil E. is online now
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You checks seem OK. If you have good spark while kicking, maybe the fuel system should be inspected for problems.
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Old 04-05-2016, 01:33 AM
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I had a similar problem on my 06 200 a few years ago. Turned out to be a bad ground connection at the ignition coil.
The coil is grounded to the frame via the screws. Remove the coil and make sure you have bare metal where the threaded clip sits on the frame tab. On my frame it was quite rusty.
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2015 EC200 Racing: TE bars, Rekluse Core Exp 3.0, 38mm Lectron & Ohlins S3 steering damper
2006 EC200: 2011 plastics, Rekluse Z-Start, revalved KYB forks & Scotts steering damper
1998 Bimota Supermono
1986 Duc Mille S2
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Old 04-05-2016, 01:54 AM
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Did you try with a new spark plug? I had exactly the same problem once: spark was there when inspected out in the air but not under compression in the cylinder. New plug and still runs fine.
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Old 04-05-2016, 09:43 AM
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Thanks everyone ! Think I have found the problems - as Anders mentioned, the surfaces where the coil grounds to the frame had got rusty and pigpen was also correct about the coil > ht lead because there was water and dirt in there. It starts easily and revs now and I will test it out in the dirt in the next few days.

I guess the lesson was to pay attention to the small details
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Old 04-05-2016, 03:11 PM
pigpen966 pigpen966 is offline
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Took about a month for me to find it. I was ready to signal the sweep crew with a cloud of black smoke
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Old 04-10-2016, 10:32 AM
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Default any electronics experts ?

It went bad again. My bike has a separate ignition loom and the Coil (W/Blue), Ground (Blk/W) and Engine Stop (Blk/Y) are routed along the right hand side of the perimeter frame to the coil. The 'wiggle the wires' test seems to cause the ignition to go wrong. Presumably it is the earth or coil wire that is breaking up. I think that as the fit of the fuel tank has got tighter with age, the tank may have crushed the wires against the frame (although there is no obvious damage to the insulation). The previous owner was also a very enthusiastic user of cable ties, which could also have caused damage.

What I would like to do is replace the 3 wires from the cdi plug (the bike fires up first kick when the wires are wiggled right). The cdi is the multipin connector one ME250834007. Does anyone know the specification for the female crimp terminals used in the multipin plug ? I've spent hours searching the web to no avail.
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Old 04-10-2016, 11:53 AM
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Yes I have it somewhere I think. I bought one of those plugs when I was havn my problems. I'll try to look it up later tonight.

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"So you know, that you're over the hill when your mind makes a promise that your body can't fill" (Little Feat: Old Folks Boogie)

2015 EC200 Racing: TE bars, Rekluse Core Exp 3.0, 38mm Lectron & Ohlins S3 steering damper
2006 EC200: 2011 plastics, Rekluse Z-Start, revalved KYB forks & Scotts steering damper
1998 Bimota Supermono
1986 Duc Mille S2
1975 Guzzi sidecar hack
1961 Morini Corsaro 125
etc
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Old 04-10-2016, 05:09 PM
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I found the invoice from Digikey.

The housing:
http://www.digikey.com/product-searc...ds=670-2463-ND

The front:
http://www.digikey.com/product-searc...ds=670-2464-ND

Dummy pins:
http://www.digikey.com/product-searc...ds=670-1681-ND

Pins:
http://www.digikey.com/product-searc...=670-1682-1-ND

I hope this is what you were after.
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Anders

"So you know, that you're over the hill when your mind makes a promise that your body can't fill" (Little Feat: Old Folks Boogie)

2015 EC200 Racing: TE bars, Rekluse Core Exp 3.0, 38mm Lectron & Ohlins S3 steering damper
2006 EC200: 2011 plastics, Rekluse Z-Start, revalved KYB forks & Scotts steering damper
1998 Bimota Supermono
1986 Duc Mille S2
1975 Guzzi sidecar hack
1961 Morini Corsaro 125
etc
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