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Old November 18th, 2019, 08:02 AM   #1
Tylerscott86
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The infamous gray wire...

So let me start by saying hey to everyone. This is my first post but have been lingering for a while. I purchased a 1999 ninja 250 some time ago and have reached my limit with this thing. ha. I have searched and read and everything in between trying to track a no spark issue. I have tested every connection and switch and sensor with a voltmeter. I think I have narrowed down the issue to the ignition switch and this resistor that's inline. The previous owner lost the key and installed an aftermarket cheapo switch. I finally realized this after removing it and finding out there was no 100-ohm resistor in the switch. He gave me the original switch so I took it apart and low and behold there was the resistor. So from there, I began testing the voltage on that gray wire. I installed a new 100-ohm resistor inline with the gray wire and still have right at 12 volts going to the CDI box. I tested my resistor to make sure the resistance is good as well. Just for reference, I have confirmed that the rectifier, coils, pickup coil, stator, and CDI box are all good. I installed a new CDI. What is the next step I can take or is it going to be install a new ignition switch all together? I'd like to be able to fix this without doing that but if that's what it takes I will. If I left out any info please let me know as I would be happy to dive in.
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Old November 18th, 2019, 08:36 PM   #2
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The infamous gray wire. Haha. PO lost keys and installed a cheapo Chinese switch. It doesn't have the 100 ohm resistor. I installed one inline on the gray wire to cdi but still have 12 volts going to cdi which is not good. So I'm scratching my head on my next move.
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Old November 19th, 2019, 02:17 AM   #3
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Did you measure resistance of resistor before installing?

I wouldn't trust PO's work. Trace grey wire from ignitor all way to ignition-switch. There may be other wires attached to it.
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Old November 19th, 2019, 04:02 AM   #4
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Yes I have measured resistance across the resistor. It shows that it's good. Just not voltage wise. And I didn't think of tracing it back looking for another connection. Good catch. I'll do that next.
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Old November 19th, 2019, 09:56 PM   #5
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It's not absolute voltage that matters, but voltage differential. Fully-charged battery just after ride or off charger is about 13.5v, so 12v at grey wire would be detected correctly. Measure voltage by back-probing ignitor connector with key ON:

- grey = ?
- blue/red = ?

Also determine pin-outs of aftermarket ignition-switch and verify it matches factory unit. Then measure input-voltage and output-voltage at all output terminals.
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Old November 20th, 2019, 06:27 AM   #6
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Quote:
Originally Posted by DannoXYZ View Post
It's not absolute voltage that matters, but voltage differential. Fully-charged battery just after ride or off charger is about 13.5v, so 12v at grey wire would be detected correctly. Measure voltage by back-probing ignitor connector with key ON:

- grey = ?
- blue/red = ?

Also determine pin-outs of aftermarket ignition-switch and verify it matches factory unit. Then measure input-voltage and output-voltage at all output terminals.
Will do this as soon as I get home this afternoon. Thanks. And just for info my battery is brand new and fresh off the charger so that does make sense. Will report back after my findings.
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Old November 21st, 2019, 02:53 PM   #7
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I thought this thread was about my hair for a second.
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Old November 21st, 2019, 06:24 PM   #8
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To check the resistor turn the bike on and start it so that current flows through the resistor and then measure the voltage across the resistor. Then measure the battery voltage. Deduct the volts across the resistor from the battery volts and you will have the answer.
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Old November 21st, 2019, 07:03 PM   #9
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To check the resistor turn the bike on and start it so that current flows through the resistor and then measure the voltage across the resistor. Then measure the battery voltage. Deduct the volts across the resistor from the battery volts and you will have the answer.
Will do as soon as I catch an off day. Just haven't had time to test and report back. Thanks everyone for the advice.
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Old November 22nd, 2019, 10:28 PM   #10
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Just wanted to report back. Got all electrical sorted out. Cleaned the carbs up. Changed oil and filter. And she runs like a champ now.
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Old November 22nd, 2019, 11:13 PM   #11
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Hey, good job!!!
What was problem?
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Old November 23rd, 2019, 06:18 AM   #12
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Quote:
Originally Posted by DannoXYZ View Post
Hey, good job!!!
What was problem?
Apparently all I had to do was check my spark again after installing the resistor. I was originally looking for a certain voltage till I was told it just has to be different to register. She was sparking strong. So I had to clean the Jets on the carbs and adjust the idle a little and she runs perfect now.
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