Any Electric Nerds. I need help.

[Markblaster]

Got a 84 Suzuki TS250 engine that needs wiring done on it.

The engine is in a grass kart. More info here about it.
http://www.blasterforum.com/threads/new-toy.65450/

CDI 32900-13A00 / 070000-1200
Wires that come out of the CDI box = 7
1x Red with green line
1x Blue with red line
1x Black with yellow line
1x Black with White line
1x White with Blue line
1x Black with red line
1x Black

Wires that come out of the engine = 7
1x Black
1x Blue with red line
1x Red with green line
3x Yellow
1x Black with Red line
1x Black with White line
1x Blue (This one is under the sprocket. I'm sure its for natural light)

This is the blue wire listed above.

Stator

Black/white earths to middle.

Kill switch.

Coil

Is this all will be needed to get the engine running. Short blue wide is earth from engine to the frame.

 

[Markblaster]

Found this wire diagram.
https://public.bn1.livefilestore.co...K0asphOw/TS250.JPG?psidu003d1&rdrts=151657295

So I will not need the Yellow wires from the stator to make the engine start and run? Looks like they are just for the lights and other electrics

 

[Markblaster]

This look ok? The ones I highlighted are the only ones I need. Going to get some wire and plugs tomorrow morning. Red dot is the only sport 2 wires meet.

 

[Markblaster]

Did some work on it today.

Tested the stator and it is all in range of what the service manual says.

Primary coil standard resistance: 122.4 & Pick-up coil: 110

Tested the kill switch and it works fine.

Tested the coil. Primary coil standard resistance was 0.4 & Secondary 3.10.

Tested the spark plug lead and that is fine.

Ended removing all wires off the stator and re-wired it and installed automotive plugs on the CDI, Kill switch and stator so it is all easy to remove.

Stripping.

New wires.

Still need to make earth cable from engine to frame and earth to coil.

Looks like I have to buy another coil. Going to check if I have spark tomorrow. Also brought a new spark plug today.

Is my 1st time doing wires on any type of bike.

 

[Markblaster]

Would I have to buy another TS250 coil or will any coil work?

 

[DUALSTROKE]

You have all the diagrams you need in order to make this work. You don't need a nerds help.lol I wouldn't jump so quick on buying a coil. Seems that plug cap/wire has a resistor in it and can make any cheap multi meter thrown off. Install it all, check for spark. What is the exhaust valve control unit? Is that some sort of kips/power valve setup thats controlled electronically?

 

[Markblaster]

Yeah after spending some time going other the diagram and jumping into the wires it wasn't as hard as I was thinking. Not sure what the exhaust valve control unit is there is no unit on the exhaust or exhaust port. only other plug on the engine I can see is the temp probe on the head. I think the 1985+ bikes have power valves. Maybe its for that?

Test spark today and let you know how it goes.

 

[Markblaster]

Alright tested today and no spark. Tried new spark plug and still no spark. Is there a way to see if the stator is making power when kicking the engine over?

Any tips on working it out.

 

[Markblaster]

 

[Markblaster]

Anyone got any ideas.

 

[Larry's Shee]

Ohm the coil and cap seperatly. Very common the caps go bad. Don't recall the value for the caps. All pretty much the same, see what the value is for a Blaster. Cut 1/4 inch off pug wire and install with Dielectric grease into cap.

 

[speedyslyder]

wild crazy guess.
could be a ground issue seeings how i dont think the coil was put on the bike like that
try running another ground ,perhaps on the other hole that is available
wild guess im really clueless but it wont hurt to try and is free lol
the blaster has another ground wire and coil is attached to the frame as well?
look into the grounding of that coil and or if it is tied into something else

 

[Markblaster]

Spark plug lead: 00.1
Spark plug cap: mix of readings 0.6, 10.4, 36.8 highest was 78.2

Already cut 1 inch off cap end other day.

Will have a look at that speedyslyder.

 

[speedyslyder]

i found this unless you have already saw it

http://www.cmsnl.com/search/index.php?spbmbrand=SU&spbmmodel=84+suzuki+ts250x&spbmvin=

http://www.cmsnl.com/suzuki-ts250x-1984-e-e01-e04-e17-e18-e21-e24_model14192/partslist/

 

[Markblaster]

Seen that.