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Old 10-18-2018, 08:47 PM   #1
Toony
Junior Member
 
Join Date: Jul 2018
Posts: 5
Replaced ignition, no spark

2002 model suzuki gz 250

So im going to go into a bit of detail about the current circumstances, but for those who need a quick rundown ill put the TLDR(too long, didnt read) right below.

TLDR: Replaced the ignition on my 2002 model gz250. Wiring on the new ignition was incorrect so i attempted to fix it, only halfway succeeded (at least i feel this is where the issue lies) no spark from the ignition coil.

For the longer version:

Ive had the bike for almost a year and a half, its been garage kept and barely ridden as i wanted to do some cosmetic work before i got it inspected. I lost my key while i was out of state, and didn't realize until i got home. I bit the bullet and bought a new ignition for it from walmart, which had to be orderd from them online . I assumed it would be a simple plug and play since i didn't have the handlebars locked so there was no need to cut anything. When i plugged up the new ignition and turned the key, i got nothing electrical wise. At this point i should have returned it and bought an OEM or used ignition, but i made the foolhardy mistake of deciding to diagnose the issue, knowing i was not equipped to deal with electrical issues. i discovered that electrical stuff did in fact work, but only when the key was turned in odd orientations

ON position- nothing
OFF- headlights come on
PARK/LOCKED- everything comes on, and the bike turned over(it never started as i never attempted to fully start it)

Cue to me unplugging the new ignition and pulling the wires out of the connector and re wiring them (on the ignition side, not the wiring harness side) as best i could following a wiring diagram i only partially understood.

Now all the electrical works with the exception of me getting a spark, and the lights still come on when i turn the key to locked, which as far as i know, everything is supposed to be off and the power should not be going anywhere. My turn signals only partially work, if flip the turn signal in either direction theres roughly a 20% chance that they will activate.

The primaryissue i encountered during the rewiring was the fact that none of the new ignition wires were the same color as the harness side with the exception of the red one. i used a circuit tester on the connections with the key in different orientations recording my results untill i got a good guess of which was which, I've obviously made some kind of mistake and i accept my inability to work on electrical related issues as I don't want ignorance to lead to damaged parts (assuming it hasnt already). I will admit that i blew a fuse twice on the relay next to the battery, so if theres any parts that could have been damaged please inform me.

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Well, I'm no mechanic but... actually ill just stop right there.



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