2012 EC250E Wiring Issue - No Spark

[nowheelies]

Hello all, new user here and I have an issue.

I searched the forum and was not able to find anything too fruitful,

I bought a 2012 EC250 w/ electric start. When I bought it, it didn't run (had no spark) but after a couple days work I got it going. This time around pulling it out of storage I find I have no spark again. I pulled the wiring harness to do some trouble shooting against the electrical diagram and noticed a lot of funny things: splice after splice after splice, wires leading to nowheres, etc.

My question is this, what do I need to have at a minimum connected to get spark? (using kickstarter only) By my logic I'm thinking I need the alternator connected to the CDI and regulator. CDI connected to the Ignition coil. Do iI even need the regulator connected as it just evens out the voltage for the lighting? Lastly, everything must be grounded properly. That said this is what I have connected and still no spark.

I checked ignition coil and spark plug and got approx 5kOhm for each. Checking alternator I got 12ish ohm which I believe is reasonable. Not sure how to diagnose CDI.

Any help/thoughts would be much appreciated, I will follow up with photos tomorrow.

Great forum btw, Thank!!

Jeff

 

[Neil E.]

Skim this topic for ideas. Post #26 covers the ignition requirements.
http://www.gasgasrider.org/forum/showthread.php?t=21215

 

[Neil E.]

Make sure you disconnect the key switch or at minimum have it turned on. One set of contacts grounds the ignition circuit when the key is off.

The multiple splices and wires going nowhere don't matter unless they are part of the ignition wiring.

 

[nowheelies]

Thanks for the help Neil,

I dont have the key on this bike, the key switch has been removed. This complicates things a bit, but i think the solution is to jumper two wires somewhere, perhaps wire 38 as per wiring diagram can be grounded? (see wiring diagram 1)





I confirmed numbers on alternator:
- 14.1 Ohm at stator
- 95.9 Ohm at pulse


and on the iginiton coil:
- 5.26 kOhm on plug connector
- 5.83 kOhm on ignition wire (to spark plug).


Another question:
looking at image of ignition coil, is the tab that connects to CDI wiring supposed to be grounded? (mine is)

 

[nowheelies]

And just for fun the wiring harness:

 

[Neil E.]

The key switch has two functions: OFF= 9 and 20 connected to short out the ignition, ON= 11 and 15 connected to power the estart button.

Do not ground 38 (from the CDI). It is actually 20 (38>21>20) when you follow the path. Your wiring diagram shows 21 also connecting to 22. I believe if you follow this wire, it will go to your kill switch.

Do you have a full size image of the wiring diagram? This would help me follow along.

 

[nowheelies]

Neil,

Just from the bike manual, see GasGas Website:
http://www.gasgasmotos.es/en/manuals/download-manual_enduro_2012_e_en.pdf.html

See page 17. Can zoom in pretty good

Jeff

 

[barossi73]

Im not familiar with gg estart but the key 'on' position may/maynot also open supply to lighting circuit so if theres a short in lighting circuit...no power

 

[pigpen966]

Check the coil to plug wire connection. The plug wire screws on to the coil. Took me about a month of frustration to find it.

 

[nowheelies]

Ok so I modified the electrical schematic using paint, this is what I have wired in on the bike. everything looks ok to me; one wire off the regulator but it normally goes to the key start. Can anyone see any issues?

Note: the key start is removed, headlights/brakes switches removed, E-Start removed, relay and battery removed (Also, this is not new. Completed by previous owner; it came like this and I have ridden like this so it should work.....)

 

[nowheelies]

I believe this meets the requirements for sparks:
1) Single exciter winding on the stator plus wires
2) Pulse trigger outside of the flywheel plus wires
3) CDI plus wires
4) Ignition coil plus wires
5) High tension lead plus spark plug
6) Grounds for the engine and coil etc.

(Ref: Neil E's post #26: http://www.gasgasrider.org/forum/showthread.php?t=21215)

 

[Neil E.]

Im not familiar with gg estart but the key 'on' position may/maynot also open supply to lighting circuit so if theres a short in lighting circuit...no power

This is not true unless the 2012 wiring is different than the 2011 wiring. I have also had the key switch apart so I can confirm it only has the functions that I mentioned above.

Nowheelies, I'm very busy at the moment, but I can look at the connections in more detail later on. Since the bike ran with the modified wiring, I would expect you have a bad ground or bad connection.

 

[nowheelies]

Don't sweat it too much! i got spark today so the wiring diagram is confirmed to work; kill switch blocks spark when it needs to, etc. in fact no wiring needs to go to the regulator to get spark.

Thanks for the help!

Jeff

 

[Neil E.]

Good to know it's working, did you figure out what the problem was?

 

[nowheelies]

TBH I don't know. I pulled the harness again and rechecked continuity, resistances, etc. On reassembly I got spark, I must not have had it connected properly or something was grounded that should have been.

Really appreciate the help,

Jeff