Hi There everyone.

To start off this is my First NSR but definately not my first 2 stroke!, i have a collection of a 3XV / RS250 (NS300) / KR1s (restoration). Ive wanted the NSR since my RS250 but was a bit difficult to find a good one here in AUS, over some time i found an importers in Sydney known as Old gold motorcycles and Bruce there imported me a WILD Mc21 dry clutch model for what i think was very cheap!. Since its received all new fairings (Stock look inc Tyga Suzuka 8 hour front) all professionally painted in repsol trim, some diablo supercorsas and a full rework of the suspension. However soon with come a tyga 300 kit and maybe a modern front end swap, depending how well the stock holds up .

Basically i got the thing registered finally after some hiccups with the headlight setup (bit of cash and away it went ), took it for an amazing ride around the area, very very little cruising , ran like a dream or an extremely fast dream at that!. On my way home however after waiting at the traffic lights for not even 15 seconds it just died like i turned a switch off. Tried to restart, cursed a bit and pushed to the side of the road. Got it home later that day and checked that there was no spark on ANY cylinder. After sometime with it everything is checking out fine. Coils are strong and healthy, all ignition switches and safety cutouts ie sidestand etc are working as meant to, power valves are working (TPS disconnection and reconnection). Im at the stage where im leaning on the PGM but a glimmer of hope that everything else on the bike is working and sort of controlled by the PGM is telling me another story. ANY AND I MEAN ANYYYYYY advice would be hugely appreciated as i don't want to take it to a shop and have them charge me 200 bucks to tell me a pgm is blown and thats about what they are worth to replace.

Thanks in advance for anyones help .

Regards.
Rodney.

Any signal from the pulse generator?

Spends some time on the kill switch , check that it is not faulty at all . After that work from flywheel to the rectifier - it could have blown the pgm if it is faulty , check the battery is high 12volts etc .
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NSR300

Hi all-torque,

I'm not very experimented in the PGM but i supose is similar with most CDI units.
Have you checked the PGM ouput signal for spark?
You can use a LED indicator connected to the + wire in the coil to see if it's generating the ignition signal. If there is no signal the problem surely comes from the magnetic sensor at the flywheel, check the resistance between the cables in the flywheel sensor to see if it's faulty.
In the manual you'll see the correct values for the pickup sensor, i can't recall these values but maybe someone can.

I hope it's get solved quickly.

Cheers.

@ Bushman - IF its the same part im thinking of, i tested the white 4 pin plug that sits next to the red 4 pin under the tail section. It has 2 blue and 2 yellow, or well mine has 1 blue / 1 blue white, 1 yellow and 1 yellow / white. They came back @214 ohms / 207 ohms between each colour (blue / blue etc).

@neal - The kill switch to my testing is working as with its action the power valves do their thing with the TPS test and the oil light flicks on / off with the kill switch or does that still mean there could be a problem there ?.

Whats the way to test the rectifier for an issue ?. i understand what it does but believe otherwise that theres a problem because the battery was a bit low upon the first ride because the bike had been sitting for so long.

Apologies if my questions are amateur at best, this is my weak spot when it comes to anything automotive, engines are clearly my strong point haha.

thanks heaps for the responses guys, im just too keen to get this thing rockin again!.

Rodney.

Ignition system fault-finding chart by Electrex-USA in the Workshop.

You'll also find an MC21 wiring diagram there.
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Andy.
NSR-WORLD.COM

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How many volts on your battery?

Where abouts in Sydney are you? I'm in the west so if it's not too far I can swing by and help with troubleshooting.

Battery is showing 10.2 volts. Im actually about 5 hours north of you nxrsr20 or otherwise id have loved some assistance! but i appreciate the offer none the less mate .

Ive just ran a test like to the coil connectors, with the ignition on and the light hooked up to the + battery i get a light on both connectors, unsure if thats typical or what not but thought id report back with that info in case it means something ?.

Thanks for everyones help so far .

Regards.
Rodney

Recharge the battery until you get at least 12.2-4 volts and then try again .
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NSR300

No dice unfortunately Neal. Still dead as a door nail .

Purchased another PGM3 From Germany. Fingers crossed this is the issue, if not i think it might find itself on ebay!!.

Have you checked the kill switch wiring? An easy way to do that is to have the handle bar in a few different angles. I had that occur to me and a bike would not start with it in the full lock position.

Checked all your fuses too?

Kill switch is working correctly. Oil light is on when its on, oil lights off when its off, ill have a go with steering position though .

Fuses all fine, its the strangest issue as everything is working as it should, but no spark on either cylinder, so its something that has control over both cylinders which is why im assuming PGM. Bit frightening after all the research to learn how easily they die to. Seems everything has a weak spot, the Aprilias / suzuki's being a bit more dramatic than the NSR though hahaha.

Are you getting pulses into the PGM from the flywheel?

all-torque wrote:
...no spark on either cylinder, so its something that has control over both cylinders which is why im assuming PGM. Bit frightening after all the research to learn how easily they die to.

It's very rare to see a PGM-III fail on the ignition side, however you are looking at a box that's anything between 21 and 24 years old now, so anything is possible. The "common" failure was due to poor maintenance of the RC Valves, something we've strived hard to largely stamp out on NSR-WORLD.

10~15 years ago, we'd see "blown" PGM's 2~3 times a month, now we see more like 2~3 a year.

Did you read the Electrex-USA trouble-shooter?
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Andy.
NSR-WORLD.COM

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Please DO NOT PM me for technical advice. My time is precious, and you will probably receive a faster response on the Forum anyway.

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