It's another spark issue

ok so custom wiring isn't anything new for me but I'm left scratching my head on this one. I'm pretty sure it's not getting any spark at all. I tested the coils and resistance is good but my two...(ok three) concerns are my wiring according to the diagram(attached), spark plug caps, and the tci unit. Any help as usual is greatly appreciated.

 

is it the same as this? print it and mark each wire as you check it. never overlook the obvious and take nothing for granted

 

Looks almost exact I might be missing the ground on the tci.
Edit: I just realized I checked that today

 

Waiting for the chacal/heavy hitters chime-in...

 

Have you checked the coil resistances? Plug cap resistances? Wires for ground faults? Ignition pickups?

 

What's the resistance supposed to be on the plug caps? Coils and ignition pick ups seem to look good in terms of resistance. Grounds seem to be good even though that has been a problem before.

 

5K ohms each +/- 20%

Well, either the plugs are sparking or they ain't! Have you pulled a plug, grounded it to the head, and cranked? Any blue sparks, even teeny-tiny ones? If not, you've got to start tracing wiring back from there and make sure things are correct per the above (proper) diagram.

 

Looks like the caps might be the issue of no spark. Some are giving 5k in resistance, one much higher, and one not at all. I guess it doesn't hurt to order new ones. Expect an update tuesday.

 

Still no spark so probably the tci unit. Anybody have a spare one?

 

So I'm thinking it might be the coils, what do you guys think?

 

Could be a bad wire connection to the cap(s)......the cap has an internal "spike" that pierces and screws (literally) into the center of the plug wire (the actual metal conductor wire at the center).....might want to unscrew the caps from their wires, cut a 1/4" of wire off the end, and re-install the caps, giving you some nice, tight, juicy and fresh wire for that spike to, umm, penetrate.........

 

So a little circumcision and then test

 

Eggs-actly! Although it's really a little more Lorena-Bobbit "guillotine" action rather than a straight circumcision........

 

ouch poor xj

 

So after going through some wires I found a bad ground(now fixed) and an additional wire that was not hooked up correctly. Now both primary and secondary coils appear to have resistance(see attached) but alas no spark. The pickup coils have the correct resistance too. I'm left scratching my head. I'm sure it by now it has to be the tci unit.

Just to recap:
-New spark
-Resistance good on pick up coils and stator
-Wiring appears correct, continuity good, and grounds connected

 

I had a similar issue and it ended up involving the clutch safety switch and the kickstand safety switch. The circuits those would be connected to need to be completed then the igniter should come back to life. These kind of look rather generic for wiring diagrams so I'm not even sure your model has the kickstand and clutch safety but, worth a shot I guess.

 

Yeah those aren't even hooked up. I bypassed all the switches and relays. Are they supposed to be hooked up if I simplified the entire harness?

 

I mean as long as the ignition box is seeing what it's supposed to be seeing volt wise then bypassing shouldn't be an issue. If there's any spare (unused) pins coming off the igniter, that may be an issue. I need to get my book back and I might be able to see what the volts at the pins are supposed to be.

 

there is also the neutral saftey switch and of course the sidestand relay and diode block.

this link while not for your bike tells how to disable the sidestand, clutch, and neutral safety switches. scroll over the component with your mouse.
http://frankjohansson.com/stuff/xj550/XJ550ElectricalDiagram.html

relay test
http://www.xjbikes.com/forums/threads/how-to-test-a-relay.6809/#post-57590

 

What should the black/white wire coming out of the tci be connected to?

 

It looks like that's the sidestand relay safety. I don't know if it's an input or an output though. If the rest of the power is working on the ignition box you may want to hook a volt meter up and if it's an output probably want to stick like a 6ohm resister on it and ground it. If it's an input you'll need to know what the volts coming into it are supposed to be and run power to it through a proper resister (if needed) to make sure the igniter isn't overloaded which could cause it to fail. I'm more of an automechanic with motorcycle tendencies but, at the risk of giving bad advise most computer controled things tend to take inputs around 5v on cars and most of my toys have been 6v on bikes... That's not 100% though so... just hook the voltmeter up first.

 

That wire needs to be open (not connected). With a working safety circuit the side stand relay normally closed contacts will ground the black/white wire disabling the TCI whenever an unsafe condition exists - side stand down and out of neutral.

Also, be sure to check spark one plug at a time with the others hooked up and installed to provide the complete circuit required for the wasted spark ignition system.

 

I'm having this exact same issue with my '82 xj650. It ran (rather poorly) when i bought it back in October, so I took it apart and when I put it back together, I had no spark. I've been desperately searching for a bare-bones wiring diagram to help me through this, but I haven't found that yet. Please keep us updated on your progress and I'll be sure to chime in if I figure out where my gremlins are.

 

Check Polock's post at the beginning of this thread. Minimum wiring diagram. Looks like Greek to me, but i is afeared of electricity. If you're too lazy to scroll back, here's a link...
http://www.xjbikes.com/forums/threads/its-another-spark-issue.59205/#post-450056

 

Please start your own thread. Same symptoms does not always equal same cause.

 

Checked and double checked everything I'm now seeking an xj550 to test the tci unit on if anybody can help me out that would be great. Of i will pay for shipping/ insurance etc.