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Old March 9th, 2019, 01:25 PM   #1
J_man85
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'06 ex250 no spark

I just got this bike and have been pulling my hair out ever since. Coils both checked out good I'm getting power to them, and I finally got it to start turning over after fixing the darn safety switches but still no spark. The cdi box is supposedly good beings it came from a wrecked bike. I checked the pulse generator and it is in speck.. Is there anything off the wall or something stupid I'm overlooking? I'm almost thinking the cdi but not positive. Also I have the starter wire jumped at the fuse box because it wasn't sending power to the solenoid.. Any help would be appreciated
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Old March 9th, 2019, 01:34 PM   #2
csmith12
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Welcome!

Someone will chime in with a proposed solution or things to check on your bike.

Good luck!
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Old March 9th, 2019, 02:37 PM   #3
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One of your interlock safety switches is not right. As indicated by bypassing starter solenoid. That is not "fixing" the problem because you need to restore to factory-fresh condition. Remove solenoid bypass and measure all the switches to determine which one is not operating to factory spec:

- neutral-safety switch resistance to ground in neutral. OHMS = ???

- clutch-switch. Disconnect connector and measure directly at switch terminals.
Lever-OUT OHMS = ??? Lever-IN OHMS = ???

- sidestand switch. Disconnect connector from harness and measure between terminals
Sidestand-UP OHMS = ??? Sidestand-DOWN OHMS = ???

- white wire going into ignition-switch VOLTS = ???

- ALL wires going out of ignition switch with key ON. VOLTS = ???

- key ON, wire between ignition switch to RUN switch, VOLTS = ???

- key ON, wire between RUN switch ON and START switch, VOLTS = ???

- key ON, wire out of START switch to starter-relay, PRESS START switch, VOLTS = ???


Also make sure you have correct ignition switch and CDI box. Using ones from previous generation will not work. Anti-theft circuitry checks to see if switch and CDI was original to that bike. If not same, it won't start or run engine.

Last futzed with by DannoXYZ; March 9th, 2019 at 04:30 PM.
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Old March 9th, 2019, 03:36 PM   #4
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are you using the stock switch and key.....
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Old March 9th, 2019, 04:05 PM   #5
J_man85
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Thanks csmith12. I bypassed the ignition switch due to being destroyed when I got it. The kick stand safety switch wire is looped together to rule it out. I haven't checked the clutch switch yet. I'll check the ohms on everything again and post that.
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Old March 9th, 2019, 04:25 PM   #6
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Hmmm, CDI box won't run unless activated by actual matching ignition-switch.
Key-code (little tag on ring) on keys must match code on ignition-switch.

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Old March 9th, 2019, 05:02 PM   #7
J_man85
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DannoXYZ, I checked the clutch switch and needless to say I have it turning over now without a jumper going to the y/r wire but still no spark.. �� these bikes won't run without the exact key for the ignition switch?? What if splice all ignition wires together?
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Old March 9th, 2019, 05:10 PM   #8
J_man85
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And another thing is the head light doesn't come on every time I turn it over . every couple of times I turn it over it comes on when I let go of the starter switch and sometimes it wont
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Old March 9th, 2019, 07:05 PM   #9
J_man85
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After all the checking and over thinking everything over and over again and trying different things it came down to one little teeny tiny cotton pickin resistor. Now the fun part of re-wrapping the wire harness and figuring out what to put the motor on. Thanks to everyone for the for the help
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Old March 9th, 2019, 07:29 PM   #10
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Quote:
Originally Posted by J_man85 View Post
And another thing is the head light doesn't come on every time I turn it over . every couple of times I turn it over it comes on when I let go of the starter switch and sometimes it wont
Yeah, headlight doesn't turn on until engine is running fast enough. Sometimes cranking may get it going fast enough. But engine really has to be running.
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Old March 10th, 2019, 06:36 PM   #11
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Also if bike had been sitting for a while, be prepared to completely disassemble carbs for thorough cleaning.
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Old March 10th, 2019, 07:59 PM   #12
J_man85
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Yes sir I plan on it I just didn't want to do much to it til I got it to fire up. I ran it for maybe 2 minutes last night and will be draining all the fluids and cleaning the carbs.
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