It seems I'm having major bad luck when it comes to my NSR. First I get a fracture in the flywheel, all the way around, making it possible to turn it a couple degrees thus changing the ignition. Bought two new flywheels. Problem solved...for now. It went perfectly on my testrun untill it dies after 200m during acceleration, just like someone hit the kill switch.
First thought was that the pulse generators was broken since it seems that on of them had got hit by the broken flywheel. Though when checking them with my multimeter they both seem to sense the plugs on the flywheel. To be certain i switched with a spare pair that should work but still no spark.
Second thought was that the PGM3-unit had broken. And since it's hard to measure with a simple multimeter, the outgoing current from the PGM to the coils i had to replace the PGM with one I knew have been working before. But still no spark.
This has went forth with changing parts I thought was broken, but without any result. I've got 4 different wiring looms that i have tested, 2 race and 2 stock, changed the coils, the spark plug, battery, stator wheel, fuses and flywheels. I've checked the kill switch, the ground (-) connection, the rictifier, the generator (witch shouldnt matter since I allways have a charger connected to the battery), the side stand switch and probably some more things I've forgotten to mention.
The only thing I haven't changed is the switch indicator assembly, but will try this soon when I get hold of one that should work. It sure doesn't look good, with exposed wires without isolation at some parts, and when testing it with the multimeter it seems sometimes that when in for example 1:st gear the signal says it's in 2:nd (according to the wiring diagram)
But can this really be it? Shouldn't there still be a spark, even if the CDI thinks that the bike is in 6:th gear with the side stand out?
Look at this really nice picture that i have spent several seconds on in Paint and see if you find something I should add or correct. This is the way I think of this problem.
Any help appreciated, and if you had the time to read this far maybe you have time to come up with a solution to my problem _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
Wow,you have done a lot of checking to come up with nothing,these NSR's are trickey ,mabee the ignition where the key is ,might be bad ,some of these guys on this forum are pretty sharp,come on dave I know you've read it or matt from tyga
Hmmm, I'd add short to earth to the broken wiring loom line...
Does it run fine stationary at all revs?
Does it run fine if you pull away and remain slow - don't accelerate?
Did you refit the flywheel EXACTLY right? It may be that the wheel is slightly out, but close enough at low RPM for the motor to fire. A the engine speed increases so does the advance, pushing the pickup too far off to work... _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
@Dave
The problem is that it doesn't give a spark...at all! The bike went fine after installing the new flywheel, then just died. No spark since.
I've refitted the flywheel a couple of times when switching between the two I have, wich is a bit tricky, but I think I got it right now.
If I should sum up all my problems into one question it would be:
Should the bike run (give spark) even if the side stand is down and the switch indicator says the biks is in 3rd gear (or any other but neutral)?
Why this is the "main" question is since I've tried with everything else as far as I know. And by that I mean removing components that I think might be broken causing no spark and refitting spares that should work.
Also, I should probably say that all other electricity works fine, the RC-servo motor, lights, incoming signals to PGM from pulse generator, sidestand, switch indicator (witch might be broken and send wrong signals..) _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
I've removed my sidestand switch, so I'm going from memory here, but I believe the motor should cut out if it's put into gear with the side stand down.
Now I can't recall if it's a normally open or normally closed switch.
Try disconnecting the switch and running the bike. If it now runs you've found it. If not, short the connector ends together and try again. Likewise, if it now runs you've found it.
Sounds to me like you have a bad Gear position indicator though, as it should reflect what the bike is actually doing. Has the wire splice been done on the loom you have? _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
I've tried with the sidestand up and dow, tried with the switch removed and checked with the multimeter that the signal changes when the stand is put down. I also don't know wether there should be a signal if the stand is down or when it's up. I cannot remember any time when I've ridden the NSR and, when in a gear, it stoper when i put down the side stand.
My guess is also that the gear position indicator is bad (I called it the "switch indicator" ) but I don't have a spare so I can try to change it. Thats why I wounder if it really could be it. _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
Well all the switch does is earth a different wire for each gear. Do it manually. _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
If you suspect the GPS, disconnect it and run the neutral (Gn/R) to earth (ground) to make the PGM "think" it's out of gear. That way the side-stand switch position shouldn't matter, whether it's faulty or not. _________________ Andy.
NSR-WORLD.COM
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Smart thinking, never thought of that. Will try this tomorrow. But my guess is that I'll be back... _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
You're running out of stuff to change man, have faith! _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
Just back from the garage. Darn cold outside, 1 dm (4 inch) of snow at the ground and a warming temperature just below zero. Why is not my garage heated?!
Back to topic. As I said before I would I am now back, back to square one, still no spark. Seems like all the incoming signals to the PGM is correct, at least what I've measured with the multimeter, and in the instrument panel the lights for the side stand and neutral is indicating that the signals is going through the PGM correctly. Something I've forgotten?
Incoming signals that the PGM need to send signal to coils are from the
- pulse generators
- GPS
- key ignition
- kill switch
- side stand switch (wich might not be needed but doesn't matter since it works)
Is there something else the PGM is taking in to consideration before sending signals to ignition coils? When turning the igniton on the lights in the instrument panel lights up, but is this guarantee enough to say that the PGM gets power? The kill witch I'm pretty sure there is no problem with.
If I can rule out errors at the individual parts, like pulse generator, GPS and stuff I can locate the problem to the PGM, ignition coils and the wires between them. _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
Throttle position sensor on the side of the carbs. Maybe it's shorting to earth? _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
Hi everybody. I'm back now, standing in my garage freezing my behind off while typing this appeal for help.
Recently checked the TPS, if it's connected to ground, which it wasn't.
Going to fit the race wiring loom. Then I don't have to worry about wires, to e.g. lights, accidentally connected to ground (if that could matter).
To get the discussion back to life:
What is needed for the PGM to gic spark on the spark plug?
On the race wiring loom there are two plugs (?) for the PGM (black and white), one for the pulse generator (white), one for the generator (red), one for the TPS (gray), one wire for the ground (green), two wires for the battery (red and green), one plug for the rictifier (white), one for the ground (?) on the thermostat (white), one cable to measure temperature (?) on the thermostat (green wire,black insulation), four plugs to the coils (black), two plugs to the power jet selenoids( green and white), one single wire and one plug (white) to the RC-servo, one plug to the oil pump (red), one plug to the kill switch (red) and at last one plug to the instrument panel (black). I think thats it (can upload a pic later if needed).
Which of these plugs and cables can be disconnected without effecting the spark?
EDIT//Now it should be correct with colors and where the plugs go _________________ MC21, GP-Replica (Daijiro Kato, Telefonica Movistar Team 2001)
Last edited by Bodoe on Thu Mar 09, 2006 4:13 pm; edited 2 times in total
Have you lokked over the wiring diagram for the bike? If you follow various lines, you'll be able to see what is and isn't needed by the PGM. _________________ MC21SP Plaything
BMW F800GS Bumblebee
Triumph 9551 Daytona Big boys toy
FJ1100 Sporting relic
GTS1000 oddball
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