2 Spark Related Questions....

First off it is a 2006 Husqvarna SM510R. I was going to the dealer to get an inspection sticker and wound up stopped at a light. The bike was idling fine without any hint of a problem. Just before the light went green the bike just stopped running. Left sitting in traffic on a non running bike I was left to push the bike to the side of the road.

Looked into the reasons behind why it will crank and not start and discovered that there is no spark. Checked the output of the generator and saw some voltage on both the primary and secondary windings but no idea if it is the correct voltage or not. I figure I should get to the bottom of this the correct way so I can ride/race my bike this year.

question 1

Anyone have any suggestions as to what to look at in regards to a no spark issue. I am going to be taking the bike apart and checking all of the wiring harness to verify that nothing is shorted to the frame. What next?

question 2

Does anyone have the pages of the service manual for troubleshooting the ignition system. I have a copy of the service manual but it is apparently a draft copy and the pages for troubleshooting the ignition system aren't complete.

Thanks

Joel

Sounds like yer on the right track in terms of hunting down a short. Can't tell you how many times a faulty kill switch has been the cause of HOURS of wasted time looking for a bigger problem though!

Did some digging this morning and discovered that the spark plug boot has seperated from the sprak plug wire coming from the coil.

I measured the impedance between the end of the spark plug wire and the mounting tab of the coil and got a reading of approx 6 KOhm.

I then measured the resistance from the spade terminal that connects to the CDI box through the harness to the mounting tab of the coil and got a very low inpedance reading. Almost equivalent to the resistance in my meter leads.

One last impedance measurement was done of the spark plug cap from where the wire to the coil should be connected to the the cap that connects to the top of the spark plug. This measurement was in the 5 KOhm range.

Do the parts exist to repair something like this? Is a replacement spark plug cap that screws onto the spark plug wire coming from the coil something that would repair this? Or, am I done riding until I order a coil from Husky and install it to determine if this is in fact the root cause of my bike not running.

Thanks

Joel

If you knew someone with a bike like yours, you could swap them out. My bet is this is indeed your problem and it probably got some moisture in it somehow. I had the same exact problem with bike a while back. New coil did the trick, but if you could borrow one first, that might be cheaper...

Yeah, not too many people around me that own Huskys that I know of so the swapping parts thing is out.

I ordered an NGK replacement sprak plug cap from my local dealer and will buy some HT wire and put everything back together and hope she runs sometime this week.

If not, new coil here we come!

Joel

No luck with the new wire and spark plug cap.

How would one go about testing if the signal from the CDI to the coil is correct? The brown/white wire that goes to the coil comes from the CDI correct?

Joel

The 06-07 husky s with the starter\killw button short out all the time. most likely your problem.

What would I look for to see if I have this issue?

Joel

Well, I finally grew balls big enough to try my Vortex ignition box, hoping I didn't smoke that one too, instead of my stock CDI and the bike fired right up. This prevents me from street riding the bike, no head and tail lights with the Vortex, but I will at least be able to get back on the track in the up coming weeks.

I have read a couple of threads about stock CDI boxes dying. Does anyone have any ideas as to what is killing the CDI boxes? I haven't completely proven that mine is bad, I will re-install the stock CDI and give it a shot again before I say it is definitely the CDI.

Any ideas on cost of a new stock CDI?

Thanks

Joel

So, the end result of all of this was that my stator was apparently no good. Contrary to my last post where I indicated that the Vortex ignition took care of it.

After getting the bike running with the Vortex I attempted to start the bike the next day to no avail. I gave up for a couple of days while the local suspension guy did some work and then brought it home to try again. Wound up getting the bike to start and run by using a jump pack in addition to the battery. Figured I just had a weak battery. Charged the battery overnight, packed the bike up and headed off to the track for a track day. Could not get the bike to start at all at the track even with the jump pack. Packed all my crap up and headed home, kinda aggravated about the whole situation.

I wound up thinking about the situation all the way home and figured the spark I was able to get using the various methods always seemed a little on the light side so after reviewing the service manual I figured it must be the stator. I measured all the resistances on the stator on the bike (there is another post on here regarding that) and another stator I had access to and there were slight differences between the two so I said let me throw the other stator on and see what happens. Threw in the other stator and the bike lit off instantly when I hit the start button.

So tomorrow I am off to NHMS to see if I can get through the weekend of racing with a running motorcycle.

Hopefully this post will help someone in the future that searches on "spark issues".

Joel