XTZ660 No spark

[mucca]

Hi everyone,

Am in need of your help yet again. I've got no spark on my 1995 XTZ660. I've got power to the red and white wire at the coil, the engine cranks over, battery voltage is good, side stand switch has been removed and bridged out. The clutch switch has also been bridged out but still no spark.

Any help would be much appreciated.

All the best.

[motorang]

Maybe the battery is not as good as you think, cranking hard but leving not enough voltage for the TCI.
You could try helping with jumper cables from a full car battery to see what you are at.

If it works then, the battery is the culprit.

Andy

[mucca]

Thanks Andy,
I'll try a car battery and some jump leads. and let you know.
Regards.
Mick

[dzl]

If it is cranking ok then no issue with clutch or side stand switches. I would check the stator pick up coil resistance at the TCI plug first. If is the same as an XT600e is Green/ white & blue/ yellow wires should be about 200 ohms. If thats ok, check is getting small voltage pulse on those wires when cranking. Have you checked ignition coil resistances? primary winding should be about 4 ohms and secondary about 20K ohms at the end of spark plug lead to ground.

cant say Ive ever seen a manual for the XTZ660. Does one exist? Am presuming electrics similar to XT600e?

[mucca]

Evening all.
I've just been checking the voltage from the battery and noticed that the neutral switch diode has turned to dust!!
Will this be the cause of no spark?
Thanks again for the help.
Mick

[dzl]

Short answer no. If diode is open circuit it would prevent starter cranking circuit from operating when in neutral but is irrelevant if you have shorted your clutch and side stand switches anyway. You should repair diode and reinstate your clutch and side stand switches as they arent your problem.

[mucca]

Thanks mate, I've put everything back. Jump leads to the battery, coil checked, cranking but still no spark!!
Do you think it could be the ignition/cdi unit at fault?
Thanks again.
Mick

[motorang]

Thats quite possible, yes.

You did try another spark plug?
You may also try removing the spark plug cap and fixing the end of the wire about 6 mm from some negative ground like a cooling fin. If theres a spark then the cap is bad.

Andy

[mucca]

Hi Andy I've put a new spark plug in and a cap.
Any idea how to check the ignition unit?
Regards.
Mick

[dzl]

Mick as I previously mentioned you need to check the basics first that is presuming you have a multimeter and know how to use it?.... check the stator pick up coil resistance at the TCI plug first. If is the same as an XT600e is Green/ white & blue/ yellow wires should be about 200 ohms. If thats ok, check is getting small voltage pulse on those wires when cranking. Have you checked ignition coil resistances? primary winding should be about 4 ohms and secondary about 20K ohms at the end of spark plug lead to ground.