1972 suzuki ts 250 ignition switch is broken. Wanting to find out what wires to hook up at the ignition switch for the magnito to work. Dont care about anything else electrical, just want it to get spark. thank you

Yes. you may need to make some engine mounts to fit the new engine to the old frame, but you will also need to transfer the electrical harness from the RM to the TS chassis.

If a fine pick won't work you could try super-glue carefully applied between the broken halves, or if the key is ferrous (steel) try a neodymium magnet (which you can find in an old hard-drive).

YES THESE ARE ALL ON THE SAME FUSE , YOU SAY YOU HAVE CHECKED THE FUSE, NEXT STEP TURN HE IGNITION ON TO THE PARK POSITIION THIS PROVIDES A SEPARATE LIVE FROM THE IGNITION SWITCH TO THE REAR LIGHT, IF THE REAR LIGHT COMES ON YOU KNOW THE WIREING TO THE REAR LIGHT IS IN ORDER, POSS PROBLEM WITH IGNITION SWITCH, TRACE THE WIRE BACK FROM THE FUSE TO THE IGNITION SWITCH, ITMAY HAVE BROKEN OFF, THE CONTACTS INSIDE THE IGNITION MAY BE WORN OUT, WHEN YOU HAVE FOUND THE WIRE THAT GOES TO THE REAR LIGHT AT HE IGNITION,CHECK FOR A 12V LIVE WITH THE IGNITION ON, IF YOU HAVE NO LIVE FEED, PUT A 12V LIVE FROM THE BATTERY TAKNG CARE NOT TO EARTH IT OUT, THIS WILL ELIMENATE THE WIREING FROM THIS POINT, IF IT WORKS THE IGNITION SWITCH IS AT FAULT, OTHER THINGS TO CHECK, UNDER THE FUEL TANK YOU WILL FIND THE BLOCK CONNECYOR FROM THE LIGHT MAIN SWITCH, AND THE DIP SWITCH, WITH THE KEY REMOVED FOM THE BIKE SEPARATE THE BLOCK AND CHECK INSIDE AND OUTSIDE THE BLOCK FOR CORROSION HOPE THS HELPS YOU

No spark can sometimes be a difficult diagnose, but just remember to start at one end and work your way through. Start by making sure the kill switch is not faulty, your ignition, do you have power going to the lights?, i guess your TS has points and a condensor, so, things to check would be all your connections, spark plug and spark plug cap, coil and all connectors, points, make sure they are correct gap, Most of these things can be checked with a multimeter, or unfortunately by replacing one component at a time, until you find the faulty one. It could be something as simple as a loose or broken wire. Just take a good close look at every thing starting from your key, right through to the battery.

You might find one at www.ebay.com it will show the engine diagram the charging diagram and more.

Hi and welcome to FixYa,

Initially, check for pulsating voltage on the black/yellow wire from the magneto to the ignition coil. Additionally, temporarily disconnect the black/yellow wire to the ignition switch.

Perhaps a wiring diagram would be of additional help.

Good luck and thank you for asking FixYa.

The only way to test an ignition module on any small engine is on the machine. Simple and easy.First remove the spark plug , then remove the wire that connects the module to the kill switch, its located right next to the plug wire above the laminations. Put a spark tester in the pkug boot and ground the other end. Pull the rope and look for a spark. Its that simple. If you have a spark, check the switch and wire, if you dont,check the grounding screws that hold the module to the block for a clean contact.If you still have no good spark its time to replace the Ignition module (coil).If you dont have a spark tester, ask someone dumb enough to hold it. If they jump and cuss you out you know you have a good spark

Check for a short, or partially broken wire between CDI and coil. If your wiring is goodbetween there, check between CDI and pick up.

All wires on a small engine except for the spark plug wire are to ground out the spark and stop the engine. Except a few for accessories and on generator/welders.

Knowing that, there is a small main wire that comes from your coil and leads to all other wires. It usually sits under your gas tank and runs toward your on/off switch or ignition switch. To see if it is any off your shutdowns gone bad, disconnect this wire. If still no spark then you either have a open in this wire or your magnito (coil) is bad.

If it starts, then unplug all the wires going to the kill wire and hook them up one by one until you find the one that kills the engine. Follow the wire to it's source looking for breaks in the line. If no breaks then the switch is out of place or bad.

Note: check your oil level first. Most engines come with a low oil sensor that will kill the spark if the oil level gets too low.

To check is your magnito is bad or you have a short, disconnect the wire at the magnito found by the flywheel under the flywheel cover. Tuck this wire out of the way and try to start your unit. No spark then you have a bad magnito.

I hope this diagram helps, it did me!