(NO SPARK) on all 4 new plugs

So, here's the story if anybody has any good ideas It would be greatly appreciated. I totally stripped down my 650 maxim and ( the previous owner had sprayed 3 cans of barbecue paint all over the motor without prep to the motor of any kind, the guy even painted the tank bright green while it was sitting on the tank, at least that’s what it looked like to me from the overspray). Anyways I pulled the motor and soda blasted it earlier this summer. I also took the carbs all the way apart and replaced seals and rejet for pods. So anyways I put everything back together and did some other odds and ends. The bike sat in my garage most of the summer due to lack to time ( I have a fiancé and two young kids) The last thing I needed to do was to wire up the bike before I fired her up. Well funny thing is I am an electrical tech for my day job, so its funny when you work around certain things all day the last thing you get motivated to do when you get home for work is the same thing you were just doing for 8 hours (at least me). So just last week I went out and spent a couple hours doing a basic wiring job. Fired right up off the bat and it ran no problem. So I went ahead and starting to sync up the bike with my carbtune. Bike was running pretty rich (probably due to me putting in to big of jets.) So I pulled the carbs and decided to put in a set of smaller jets. So I put the carb rack back on with the smaller jets and the bike would start. I checked no spark on any of the four plugs. So I immediately think that I have bumped a wire. So I check all the wiring pretty thoroughly a few times. It all check out. So then I grab my manual and begin from Step One in Chapter 3 covering Ignition problems. I checked the battery, I checked the primary and secondary coils, and I checked the pickup. Everything looked fine. So at this point I assume that I fouled the plugs when trying to sync with such a rich mixture. ( But all 4 plugs at the same time strange)? . So before heading down to the parts store to grab a new set of plugs I again tried the old plugs first on the coil dedicated to 1 &4 , all 4 plugs would work. Then I tried all 4 plugs on the coil dedicated to 2 &3, One plug fired. So I actually got pretty excited thinking I just had bad plugs. So I sent aside the one good plug and made sure the others were bad. (They didn’t fire) So again before I left to get new plugs grabbed the one that was firing and stuck it back in to see if it was still operational. Well the plug didn’t fire. So I ran down to the auto store got new plugs hoping to plug and play. Put in the 4 new plug and still no spark. What’s the chance of a bad or intermittent TCI unit, any help again would be greatly appreciated. I spent all Sunday scratching my head over this one?

Thanks
Sieggs_3

 

I'm dealing with the same problem. I think it would be the pick up points or the CDI. I will work again on them tomorrow and will let you know what I found.
Natan

 

Safety circuit. Is it still present? Sidestand switch, sidestand relay (if so equipped) neutral switch, clutch lever switch.

Fuse box. Did you replace the original yet?

 

Big Fitz, I removed all saftey circuits, and fuse box is updated.

 

Probably the TCI. I had issues where it would idle fine then down the road two cylinders cut out. Finally no spark on those two at idle either. Changed the TCI with one I had laying around and been riding since.

 

If you are somewhat adept at soldering, you might try opening up your TCI and checking the solder runs on the board. Cracking does happen and a quick touch-up with a soldering iron can set things right. If it proves more than that, I can trouble shoot TCI's...for a small fee of course. I offer a refresh (replace the old electrolytic capacitors) and replace any bad components I run across. If the timing chip is shot or the daughter board is cracked, it's done, I can't fix it.
Good luck!

 

Hey Robert, I was thinking a bad electrical compontent inside the TCI unit also, I actually did rip into the thing and did a visual check, I had a hard time trying to pull the circuit board out, I didnt want to damage anything by me rippping into the dang thing. I guess I'll attemp to play around with this TCI unit before throwing in the towel and purchasing a new one.

Thanks,
Sieggs

 

Be careful trying to remove the board, it is soldered to the pins of the connector and you will rip the solder runs/pads off the board if you don't do a clean extraction. There are two small screws on the back side of the TCI that must be removed beforehand as well. I can take a shot at it for you for a whopping $30 (prices going up, I'm sorry).

 

Robert, thanks for the help, I'll take a shot at pulling out the circuit board.


Thanks,
Sieggs_3

 

I had this problem and it was the TCI. I replaced, refired, relaxed.

 

I pay a bounty on dead TCI's, $5. I need to stock my parts bin with usable carcasses.

 

Does that even cover the shipping? I got a couple bad ones laying around.

 

We'll talk... I'm sure we can reach some sort of arrangement...