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178 Posts
I want to thank the guys on the forum that helped me resolve this problem. I really appreciate all the information, it all aided me in the discovery of the resolving the "ONE SPARK" problem I experienced on my Burgman 400. I read through several posts that had to do with 'washing the bike and then it wouldn't run" or something equally similar. I feel what I found might be of value to anyone experiencing stubborn starting, or a no start condition. If your scooter engine has some oxidation on the casting especially where the coil mounts, then reading this post may assist in resolving the problem. Here it is, and thanks again to everyone!!
I got the new rectifier on the bike, still just one spark!! I compared the readings I got from the original test with the test I did on the new (not used) rectifier. I set my digital meter to a less sensitive reading. Both were very close and I didn't get any feedback continuity through the diodes. I kept the new rectifier installed and put the questionable one on the shelf for the time being. I ran through a series of tests, continuity tests on the pulse generator.. removing sensors from the circuit and reinstalling them and so on. I could find nothing that would indicate a problem. I finally broke down and bought a used CDI from a 2009 Burgman 400. It was still no spark. A test of the primary and secondary circuits of the coil all checked good. There is, after all of this, a happy ending. I got the problem resolved. I now have spark to the plug. I got this resolved late last night. All the time I was doing this, I was hoping it would be something that I could discover as a test and not simply giggle some wire and it all started working and not really know what I did to fix the issue. Here was what I did. I removed the coil from the left side of the engine and did some more cleaning of the contacts, but that wasn't the problem (exactly) I saw the coil mounts were actually metal and I did a little test to ground. I found the mounts very corroded with aluminum oxide and rust. I got out my trusty wire brush and cleaned the coil mount and the motor mount area for the coil. I got out a small pair of alligator jumpers and clipped one end to the mount of the coil and the other to the chassis ground. "BINGO" it fired like it should. I will install the coil and get it started today, I am sure. "So the Saga ends of the no spark - spark plug" I bought a NEW rectifier, a used CDI, and a set of relays and tip over switch. I feel I needed the rectifier to avert an obvious future fail and since my bike has a salvage title, all warranties are void. Getting one on a recall wasn't possible. So, the total cost of getting the problem fixed was $125.00 ( $95.00 for the ICU and $30.00 for the relays) not counting the rectifier, it is something I would have bought anyway. By the way, the rectifier only converts AC voltage to DC to keep your battery charged. As far as I can tell it does not provide a direct path to the firing circuit. As long as the battery has enough power to operate the electrical system, your bike will run as long as the battery has the juice to power it. It is questionable whether or not I needed the ICU, I will know later today if mine was bad. The money I spent was a lot less than taking it do a dealer for repair. I feel I gained the knowledge to make a good repair and at least I know what makes the scooter run. I know what the relays are for, how the tip over switch is wired into the circuit and what the rectifier does. Not only that, I have a lot of feedback from guys on the forum. So, thank you all for your input.
Roger
I got the new rectifier on the bike, still just one spark!! I compared the readings I got from the original test with the test I did on the new (not used) rectifier. I set my digital meter to a less sensitive reading. Both were very close and I didn't get any feedback continuity through the diodes. I kept the new rectifier installed and put the questionable one on the shelf for the time being. I ran through a series of tests, continuity tests on the pulse generator.. removing sensors from the circuit and reinstalling them and so on. I could find nothing that would indicate a problem. I finally broke down and bought a used CDI from a 2009 Burgman 400. It was still no spark. A test of the primary and secondary circuits of the coil all checked good. There is, after all of this, a happy ending. I got the problem resolved. I now have spark to the plug. I got this resolved late last night. All the time I was doing this, I was hoping it would be something that I could discover as a test and not simply giggle some wire and it all started working and not really know what I did to fix the issue. Here was what I did. I removed the coil from the left side of the engine and did some more cleaning of the contacts, but that wasn't the problem (exactly) I saw the coil mounts were actually metal and I did a little test to ground. I found the mounts very corroded with aluminum oxide and rust. I got out my trusty wire brush and cleaned the coil mount and the motor mount area for the coil. I got out a small pair of alligator jumpers and clipped one end to the mount of the coil and the other to the chassis ground. "BINGO" it fired like it should. I will install the coil and get it started today, I am sure. "So the Saga ends of the no spark - spark plug" I bought a NEW rectifier, a used CDI, and a set of relays and tip over switch. I feel I needed the rectifier to avert an obvious future fail and since my bike has a salvage title, all warranties are void. Getting one on a recall wasn't possible. So, the total cost of getting the problem fixed was $125.00 ( $95.00 for the ICU and $30.00 for the relays) not counting the rectifier, it is something I would have bought anyway. By the way, the rectifier only converts AC voltage to DC to keep your battery charged. As far as I can tell it does not provide a direct path to the firing circuit. As long as the battery has enough power to operate the electrical system, your bike will run as long as the battery has the juice to power it. It is questionable whether or not I needed the ICU, I will know later today if mine was bad. The money I spent was a lot less than taking it do a dealer for repair. I feel I gained the knowledge to make a good repair and at least I know what makes the scooter run. I know what the relays are for, how the tip over switch is wired into the circuit and what the rectifier does. Not only that, I have a lot of feedback from guys on the forum. So, thank you all for your input.
Roger
