No Spark!! Aaahhh!

Hey Y’all, I have an ‘82 650 Seca. I’m getting no spark at any plug.

Coils passed resistance tests (both sides)
Pick-up passed resistance test

All 4 fuses look good.

Not sure what to do next.

Should I replace the CDI/Ignitor next? Where can I find one?

-Zach

 

I would make sure that the IGNITION fuse is okay, if you are still using the original fusebox (glass fuses) they can look good and not actually pass current. Turn the key switch to the on position, the RH control switch to RUN, and then test both sides of the fuse for 12V to battery ground terminal. The brittle metal "clips" can loosen or corrode and prevent current from actually passing thru them, even they the fuses look fine to the naked eye.

 

pull the ignition (if glasss) and use an inline fuse holder with alligator clips clip them to the crimps on the fuse holders.

the glass fuses I had in one bike looked good could be ohmed out but the filament was not secured to the end caps so when the current need to pass thru it did not

also make sure the run/kill switch is in the center run position(happens a lot).

when you confirm you have voltage at the fuse chase the voltage to the tci and ignition coils

 

Thanks for the reply y'all.

I have replaced the glass fuses with blade fuses and they seem alright.

I don't think any of my safety switches (sidestand, clutch, neutral) are interrupting the circuit because the starter cranks but it just won't spark.

I recently put a small battery on the bike before the temp dropped (D.C. Weather). Would an undersized battery allow the starter to crank powerfully but still not produce any spark?

I'll identify the Ignition Fuse and do a voltage test then see if its making it to the TCI.

-Zach

 

if the battery drops below 10 volts when cranking motor over bike will not start. 10 volts will spin the starter fast.
put a meter across the battery terminals and see what the voltage drops to when cranking.

you can jump the battery with a car battery but do not start the car

 

My battery has 13.45v after charging all day and dropped to 9.88v after the first crank.
I'll start with ordering a replacement (to spec) battery.

I still can't seem to pick up any significant DC voltage on the TCI. Maybe I'm testing it improperly. I've attached a photo of the unit but I can't find a wire diagram for the TCI so I'm not sure what is what.

I'll start by replacing the battery before cutting into the wiring harness.
Y'all have been a great help so far!

 

see that black wire with the white stripe disconnect it could be the problem.

9.88 volts is the issue that is the lowest level bike might start at but unlikely

you would test the red/white wire at the 4 pin connector that wire also goes to the ignition coils

 

clean any connectors you disconnect with electronic spray cleaner and reassemble with some dielectric grease.

if your carful you can slide a sewing needle into the back side of the tci connectors (there is a slot) and pull them out easily to clean . they will slide right out once you depress the lock tab.

 

also pull the headlight fuse it will keep headlight off when trying to start bike. headlight relay will trigger after the motor starts spinning

 

"see that black wire with the white stripe disconnect it could be the problem"
Does that mean, that he should disconnect the black/white wire or does it mean that disconnected, it could be the problem?
Confused.
Cheers, 50gary

 

that black white wire is used to shut down tci via sidestand relay. sometimes it will just shut it down. so when it is disconnected tci will work.

I think it is the first sign of a tci going bad when all safety circuits operate properly bike wont start, disconnect bike starts
I have a tci that works when black/white wire is disconnected bike wont start when connected
. when I put in my other tci it starts when wire is connected

disconnecting that wire is same as pulling sidestand relay


his problem is low battery voltage

 

The black/white is plugged in but the pic was at an awkward angle. However, an appropriate battery will be my first step.

Again, I don't think this is a safety switch problem because the starter cranks but no spark.

-Zach

 

Just ordered a new battery. It'll be here by the 29th.

I'll update the results of the battery swap. Keeping my fingers crossed...

-Zach

 

New battery came in.

It gave me a stronger turn-over from the starter but still no spark...

Any ideas?

-Zach

 

with out the voltage drop test it is guessing .
try a new to bike tci it is always good to have a spare.
or find someone who is still riding (my bikes are all in winter nap time at 8 degrees or less ) to real world test your tci.

contact 750maximseattle xj650 Maxim Part-out with fairing & backrest
he sells lots of parts may have a known good tci to sell you

Chacal has known good tci for sale. maybe Hogfiddles has some too.

as far as getting one tested put a request in the for sale wanted section of the forums.
if come spring time or warmer weather you still need it tested contact me. I do it for cost of return postage.

 

if you are getting voltage at the tci red/white wires and all the other components check out in the starter circuit with voltage there as well tci may be the issue.
check the voltage at tci when cranking again the 10 volt rule comes into play.
clean solid connections are the key to avoiding voltage drop .
fully charge battery then
test voltage drop at battery
at main fuse output.
at input and output of ignition fuse
at tci
at ignition coils

if all pass the drop test and all components ohm ut correct spec it is time to look at tci.

have you tried starter fluid

 

Thanks, I'll run through the voltage drop test and start the troubleshoot that way.

In the meantime, I'll try to track down a TCI and find someone to test mine on their bike.

Are there any other Xj bikes that have a compatible TCI or do I need to find an exact match?

My bike usually starts immediately when it has spark so I don't think it needs and starter spray.

 

You have a 82 650 seca which is/should be non yics motor you need a tci from 80 or 81 non yics 650 or 82 650 seca

should have a green label or a black label from the midnight 650

tdi14-08 (seca) or tdi14-02 (650 maxim)

 

Correct. This is the non-yics. I've sent a few messages looking for tci.

 

I've found a replacement TCI.

We'll see what happens when it arrives and I get it plugged in!

-Zach