I have a fym 250 which has no spark at plugs no power getting to kill switch & a box which is black in colour under l/ hand panel which has been on chain. could this be the course
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the things i would check are the pickup coil, the ignition coil, cdi box, the ignition switch and the kill switch. I just purchased a 4 wheeler that they changed everything electrical on it. come to find out the kill switch was melted onto the muffler causing it to be always activated. if you get a repair manual or look hard on the internet you can get the proper readings to ohm test your pickup coil, ignition coil and cdi box. the ignition switch can be tested with a test light and the kill switch should not be grounded unless activated. (hook a test light up to the positive side of the battery and then touch the kill switch wire. if it lights up there when not in the kill position you have a problem)
In no particular order: Check kill-switch on handlebar cluster. Check fuses. Check for loose or corroded wiring harness plugs. Check for bad pulse generator(s). Check for water in spark boxes and proper orientation.
Power comes from the fuse box to the handlebar cluster kill-switch. Check for power at the switch and after the switch with a test light or meter. If switch won't pass voltage, disassemble and clean then lubricate with silicone grease and reassemble.
Check each fuse with a meter. Remove the fuse, don't just measure it in-place. Glass (tubular) fuses can look good but still be blown. Test each one with an Ohm-meter out of the fuse panel. Same goes for newer blade fuses - pull them out and test. Fuse panel itself for blade fuses can be bad. These corrode and fatigue, cracking as base of spring contacts. Must fix fuse panel if bad as no new ones are available.
Remove seat, side-covers & tank then unplug, clean, and reconnect all multi-terminal wires going to/from steering head and coils/spark boxes. Double-check fast-on terminals at coil contacts. Double-check main ground connection to frame (under coil bracket).
Pulse generators inside right crankcase cover can fail and not send position pulses to spark boxes - pretty unlikely though. Check for continuity on each. Should show some resistance - not open. 2 pairs of wires - one pair to each pickup coil.
The spark boxes may be located either on rear fender liner under seat or one here and second one in a pocket on top of the tool-box depending on year. Spark boxes should be mounted with drain hole down and care should be used not to get water in them while washing (why would you wash a Sabre anyway?) Corrosion inside spark boxes is common on these. Some can be repaired but no new ones are available and haven't been for several years.
SOUNDS LIKE YOU MAY HAVE A DICKY KILL SWITCH . TRY TO FIND IT'S CONNECTOR( COULD BE UNDER THE TANK NEAR THE HEAD STOCK)UNPLUG THE CONNECTOR AND YOU SHOULD GET A SPARK. IF SO CHAGE THE SWITCH . MAKE SURE YOU CHECK TRY A NEW SPARKPLUG FIRST.....CHEERS.
Possibilities are; handlebar kill switch is grounding out, kick stand kill switch is broken or needs adjusting, a bad spark plug, power wire to ignition has come unplugged, bad ignition switch, ignition system needs service, coil or coil wire has gone bad. This list is in sequence of likelihood.
Do you see spark? If not, check the side stand kill switch. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the side stand kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it.
Is the handlebar kill switch on? Is it shorted out?
Check the fuses.
Check the operation of the ignition switch and all kill switches with a volt ohmmeter. Check the wiring harness. Did a wire come unplugged? Are all wires clean and with solid connections? Any abraded or pinched wires?
Is the bike in neutral and the neutral light is lit up? If no neutral light, check the neutral switch and neutral switch wire on center or side casing.
If still no spark, get CDI system and coils checked at the dealers shop.
Start with a new spark plug. Check the side stand kill switch. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it. Check the fuses. How good is the battery? Try a jump start from your car battery. Is the handlebar kill switch on?
Check the operation of the ignition switch and all kill switches with a volt ohmmeter. Check the wiring harness. Did a wire come unplugged? Are all wires clean and with solid connections? Any abraded or pinched wires? Is the bike in neutral and the neutral light is lit up? If no neutral light, check the neutral switch and neutral switch wire on center casing. If still no spark, get CDI system and coils checked at the dealers shop.
WELL A COUPLE THINGS IT IS INDUCTIVE IGNITION TCI YES SPARKS DO AND ARE SUPPOSE TO SPARK ONCE WHEN POWERING THE SYSTEM ON NORMAL BUT IF NO POWER ON ACCELERATION YOU MIGHT HAVE A IGNITOR PROBLEM OR WRONG SPARK PLUGS CHECK TO MAKE SURE WIRES ARE GOOD THE FUEL IS FLOWIG PROPELY AND THAT COIL WIRES SARE GOOD THE SAFTY SWITCHES THEN ALL GOOD YUO HAVE BAD TCI?BLACK BOX
Check the side stand kill switch. It kills the engine so that you don’t start out with the side stand down. If broken or out of adjustment, it would kill the spark. Check for a broken wire at the side stand switch and coupler. Try moving the kill switch by hand. If that doesn’t work then wire a jumper around the switch to bypass it. Check the fuses. Is the handlebar kill switch on? Check the operation of the ignition switch and all kill switches with a volt ohmmeter.
I don't know what has been done or checked so some of the following may not apply. Electrics are not my best skill but I will share what I know.
How good is your battery? A low battery can kill spark. Get a new stock spark plug for your bike. Test for spark by grounding the threads of the plug against the cylinder. Have a friend kick the bike while you watch for spark. Assuming no spark, then check the handlebar kill switch with an Ohmmeter to be sure the switch is working properly. Some bikes have a side stand kill switch. Check your bike and check the switch. Sometimes the switch goes bad.
Check the wiring harness, even under the gas tank. Are all the connectors clean and with a tight connection? Any abraded wires? Check the ignition switch also. The switch can go bad as well. Are the flywheel coils good? That's my best when no spark is present.
I hope this helps.
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