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Author Topic: DR 650 - no spark: SORTED thanks to StuartC  (Read 3535 times)

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Offline Kykdaar

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DR 650 - no spark: SORTED thanks to StuartC
« on: May 31, 2015, 08:45:05 pm »
Until today my bike started perfectly - one press of the starter motor and she purrs into life.

Whilst out on a ride today, I stopped at a shop. Starter swung over as per normal but bike would not start. After a few attempts it started like usual and ran perfectly - also as usual. About 10 km later when I stopped and switched her off, she refused to start and I had to suffer the indignation of a tow-in home ;D

Back home I started trouble shooting. Did not take long to rule fuel issues out - everything was working as it should. Turning my attention to spark I discovered that the spark plugs were not firing - whether I unscrewed the plugs, kept them in the cap and held them against the engine, or whether I stuck a screwdriver down the throat of the cap. Nada nothing.

Now to work out the reason - take my multimeter, the manual and start testing-

1. Test the continuity in the connection plug to the coil and between the two spark plugs - correct as per manual.
2. Test the generator coil continuity - correct as per manual
3. Test the power sorce coil and pick up coil - correct as per manual
4. Test the CDI unit - resistances beteen the terminals is as per manual.
5. Double check the sidestand and clutch cut out switch mods - still functioning correctly.
6. Check the kill-switch and ignition switch - functioning correctly.
7. Check the two 10A and the main 30A fuses - all intact.

Then I check the regulator - get no resistance readings whatsoever between the terminals. Look like it is toast.

But can that lead to no spark? Whilst troubleshooting I had the battery on charge with the result that the battery was fully charged and the starter motor was turning the engine over normally when I gave it a last try.

So I am stumped at the moment and will appreciate and input and help.

Thanks.


« Last Edit: June 05, 2015, 08:49:32 pm by Kykdaar »
 

Offline chopperpilot

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Re: DR 650 - no spark
« Reply #1 on: May 31, 2015, 09:26:58 pm »
Die eerste keer, toe die fiets na 'n tyd gevat het, het die starter normaal gedraai?

Die tweede keer, toe die fiets glad nie gevat het nie, het die starter enigsins en normaal gedraai?

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Offline Woestynhond

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Re: DR 650 - no spark
« Reply #2 on: May 31, 2015, 10:03:14 pm »
Does the sidestand and clutch cutout system wiring not have a join in the wire or a rubbed through wire that could be causing the problem?
Maybe a ground wire loose etc...
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Offline chopperpilot

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Re: DR 650 - no spark
« Reply #3 on: May 31, 2015, 10:14:52 pm »
The little bit of electrical experience I have is related to a DR 200.

Bought it on WD. Previous owner mentioned possible charging issue.

He supplied a spare set of stator coils and a regulator.

I checked the charging rate. 12.5V. I reckoned it to be adequate.

Sold the bike to a colleage. Ran for a while, then got stranded, while riding.

I replaced the regulator. Reading 13.5V. No more issues.

Could be that the spark coils rely on the higher current from the regulator, which should be similar at the battery, with a perfect regulator. Once the regulator goes, and remember the DR 200s was still providing current, the bike will still run for a while, before the regulator and battery does not provide sufficient current for a good spark. Might still be sufficient to swing the starter though!

I would swap regulators with Jaco. if it runs check output voltage.

If not 13.5 - 14.5V, then the stator coil, or a connection from it could be at fault.

Also check the wires coming out of the engine casing from the stator coils, as well as the connector block.

Good luck!
« Last Edit: May 31, 2015, 10:17:35 pm by chopperpilot »
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Offline StuartC

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Re: DR 650 - no spark
« Reply #4 on: May 31, 2015, 10:53:59 pm »
Check ignition switch as well, it has a resistor in if that resistance is not measured then it wont start
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Offline Crab

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Re: DR 650 - no spark
« Reply #5 on: May 31, 2015, 11:02:36 pm »
Does the sidestand and clutch cutout system wiring not have a join in the wire or a rubbed through wire that could be causing the problem?
Maybe a ground wire loose etc...

If it was one of the above then the starter would not crank the motor.
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Offline chopperpilot

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Re: DR 650 - no spark
« Reply #6 on: May 31, 2015, 11:09:51 pm »
Does the sidestand and clutch cutout system wiring not have a join in the wire or a rubbed through wire that could be causing the problem?
Maybe a ground wire loose etc...

If it was one of the above then the starter would not crank the motor.
I have never checked, but does the engine cut when kicking the side stand out, when in gear, or is it only an in-gear safety start switch?

My KTM's kills the engine. It's wiring is more complex though.




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Offline StuartC

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Re: DR 650 - no spark
« Reply #7 on: May 31, 2015, 11:36:54 pm »
Does the sidestand and clutch cutout system wiring not have a join in the wire or a rubbed through wire that could be causing the problem?
Maybe a ground wire loose etc...

If it was one of the above then the starter would not crank the motor.
the ignition resistor only blocks the spark, the engine will crank
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Offline Kykdaar

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Re: DR 650 - no spark
« Reply #8 on: June 01, 2015, 07:38:18 am »
Does the sidestand and clutch cutout system wiring not have a join in the wire or a rubbed through wire that could be causing the problem?
Maybe a ground wire loose etc...

If it was one of the above then the starter would not crank the motor.

Thanks for the replies gents - yes the above is correct. If it was one of the two cut-off switches the motor would not crank over.

Same with the kill switch - if I press it in the motor will not crank over. If it is in the run position the motor cranks over.

Check ignition switch as well, it has a resistor in if that resistance is not measured then it wont start

Did not know this, thanks will check. :thumleft:

Die eerste keer, toe die fiets na 'n tyd gevat het, het die starter normaal gedraai?

Die tweede keer, toe die fiets glad nie gevat het nie, het die starter enigsins en normaal gedraai?



Die starter motor draai normaal - motor wil net nie vat nie

 
 

Offline Kykdaar

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Re: DR 650 - no spark
« Reply #9 on: June 01, 2015, 07:40:16 am »
So the suspects at this time seems to be -

1. Ignition switch
2. Coil pick-up
3. Regulator

Think I am going to have to butcher Jaco's bike to find the problem  >:D
 

Offline Kykdaar

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Re: DR 650 - no spark
« Reply #10 on: June 01, 2015, 07:55:15 am »
One thing that bothers me is the readings I got from the Ignition Coil primary windings continuity test - the plug leading into the coil (black and black/white).

Manual says to set the Multimeter in the 1 Ohm range, but mine can only go as low as 20 Ohm which I thought should be ok.

Readings to expect is 0.07 to 0.12 Ohm. If I recall correctly, mine was much higher.

The continuity reading in the secondary winding (plug to plug) was spot on at 25 Ohm's 
 

Offline Matie spero

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Re: DR 650 - no spark
« Reply #11 on: June 01, 2015, 09:53:45 am »
hahahahaha die vinnigste wat kykdaar se dr nog ooit gery het vas gevang!!!!!

Toe ek die uncly by die huis stop, die eerste ding wat, met kinderlike opgewondenheid, geuiter word: "ek het nog nooit geweet my dr kan so trek nie!!!!"
I could agree with you! But then we both would be wrong.....

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Re: DR 650 - no spark
« Reply #12 on: June 01, 2015, 10:01:21 am »
 :laughing4: :laughing4:

Dit is f@Kken embarrising.

Daai DR van Matie het partykeer gesoek vir low-range soos hy my van n staande posisie moes sleep  :deal:

Een keer amper neergeslet toe ons koordinasie n bietjie uit was, maar alles deel van die lekker :thumleft:
 

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Re: DR 650 - no spark
« Reply #13 on: June 01, 2015, 10:05:18 am »
:laughing4: :laughing4:

Dit is f@Kken embarrising.

Daai DR van Matie het partykeer gesoek vir low-range soos hy my van n staande posisie moes sleep  :deal:

Een keer amper neergeslet toe ons koordinasie n bietjie uit was, maar alles deel van die lekker :thumleft:
Kon erger gewees het, dink net as n BMW of KTM jou moes sleep !
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Offline Kykdaar

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Re: DR 650 - no spark
« Reply #14 on: June 01, 2015, 10:07:48 am »
OK, so here is the schematic for the DR Ignition system.

My money is on the ignition coil or the regulator.

Matie will be some stripping soon >:D

« Last Edit: June 01, 2015, 10:10:46 am by Kykdaar »
 

Offline Kykdaar

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Re: DR 650 - no spark
« Reply #15 on: June 01, 2015, 10:26:19 am »
Here are the relevant troubleshooting and testing procedures.

I see LeCap is looking - please help  :3some:

 

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Re: DR 650 - no spark
« Reply #16 on: June 01, 2015, 10:45:16 am »
Swap them with Matie's bike ? Easiest way to find the culprit, should be quick on a DR.
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Re: DR 650 - no spark
« Reply #17 on: June 01, 2015, 10:52:43 am »
Swap them with Matie's bike ? Easiest way to find the culprit, should be quick on a DR.

 :thumleft:
 

Offline chopperpilot

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Re: DR 650 - no spark
« Reply #18 on: June 01, 2015, 11:31:34 am »
:laughing4: :laughing4:

Dit is f@Kken embarrising.

Daai DR van Matie het partykeer gesoek vir low-range soos hy my van n staande posisie moes sleep  :deal:

Een keer amper neergeslet toe ons koordinasie n bietjie uit was, maar alles deel van die lekker :thumleft:
Gewonder of Matie se DR vinniger is met daai 2 tappet-valley exhaust pype! :lol8:

Werk seker net op 'n V6!! :pot: :lol8: :snorting:

Sure Stuart's DR can be our designated DR tow truck! :thumleft:
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Offline Matie spero

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Re: DR 650 - no spark
« Reply #19 on: June 01, 2015, 11:52:08 am »
:laughing4: :laughing4:

Dit is f@Kken embarrising.

Daai DR van Matie het partykeer gesoek vir low-range soos hy my van n staande posisie moes sleep  :deal:

Een keer amper neergeslet toe ons koordinasie n bietjie uit was, maar alles deel van die lekker :thumleft:
Gewonder of Matie se DR vinniger is met daai 2 tappet-valley exhaust pype! :lol8:

Werk seker net op 'n V6!! :pot: :lol8: :snorting:

Sure Stuart's DR can be our designated DR tow truck! :thumleft:

Chopper, die linkerkantste pyp is n tool can...

Daar was glad nie temin lowend nie, ek was net bang ek gee daai geel DR rekmerke as ek die vol krag unleash!
I could agree with you! But then we both would be wrong.....

Political Correctness is a doctrine, recently fostered by a delusional, illogical minority and promoted by a sick mainstream media, which holds forth the proposition that it is entirely possible to pick up a piece of shit by the clean end!