This video series is going to be the most complete understanding the ignition system filled with information, tech tips, short cuts, and full diagnosis in this series
Perfection! Minute 30 helped me immensely with understanding my recently purchased 1972 Yamaha DT2250 the previous owner converted from street to dirt. I’m also tracking down a week spark. Points and condenser first. But you eased my mind when I couldn’t find a CDI box.
Just wanted to say thank you very much for making this video. I was thinking my stator was bad, but set the point gap, then tried your test, got spark, plugged the coil back in, and boom she fired right up. I was having a hell of a time before seeing this. Thanks once again man.
Omg this video is exactly what I need! I'm at work at moment so I can't wait it just yet but I'll definitely watch later so I can get the G4 started. Legendary
Kevin, with your rather impressive collection and hands on of various bikes you may prove to be just the right guy that can answer my seemingly tricky ignition replacement parts questions. I have a very old engine, special case issue, no original documentation are valid today, part numbers does not give any direct search matches. The engine´s manufacturer is no longer exsisting. It has; A Bosch coil ignition system I think 6 volts. Bosch base plate outside diameter measures 110mm named ZPT 327Z 332Z, has 3 screw holes with timing adjust. Half moon measures of coils are about 83mm, coil mount screw holes about 62mm, coil diameters are 98mm. Magneto flywheel inner diameter is 100mm, stack heght 35mm, named Bosch LM/US1/138/12/6. What bikes in parts market may fit these measurements ? I can settle for anything, fitting coils, CDI/stator/trigger replacement build, whatever as long as I can get something to once again deliver me that spark for a single cylinder, or a 12 volt charge only, to power a HEI ignition module/flywheel trigger point rig. I also have an option to go for replacing the entire system with something of smaller outer dimensions (my exsisting flywheel has realestate outer diameter of 138mm). Problem is, most shops do not list measurements, only fitting bikes, leaving me rather blind. Do you know something here I do not, or can you figure out something useful with a yard stick to this ?
@@2strokeguruIt is to my newfound experience that the answer to that question adds further confusion to bike guys :)) I guess I will have to let it rip anyway. Dont panic :D It is a 4-stroke single cyl 400ccm engine from 1957 with bike style ignition parts. Its name is Westerbeke Universal Motor Nr 10. Built as its time´s competition for Briggs & Stratton/Honda horizontal crank type applications. Flathead with bottom cam and pushrod actuated side valves. It has 2 flywheels bolted together, one small (Bosch) for the ignition system and one cast iron for mass inertia/engine cooling fan. I guess the engine bit is outside your 2-stroke scoop but yet the old timer moped/motorcycle Bosch ignition system of it ought to be in your domain. I´ve been a repair guy for most other things on wheels and belts, but I never done bikes. My 2-stroke stories are chainsaws, weed wackers and older outboard engines. If no coils/stators of today fits, a list of various bikes flywheel outer diameters that could fit inside of my 138 mm diameter realestate, fit or gap, would help a lot for refitting a completely new ignition system with magneto flywheel, stator and all.
Excellent video! Helps a lot on ignition theory and practice. Question - I have an older Suzuki coil where the red fiberboard insulator you show at about 14:14 snapped off as it became quit e brittle with age. Since there is no practical way to replace it I was thinking using a small amount of epoxy to keep wires from shifting. Thoughts?
Good evening Mr. Bergeron! Im having a little trouble with my contact breaker points for my 1973 Honda MT125 Elsinore. The points don’t spring back to the original position. It’s like sticky or stuck. I tried looking online and couldn’t find the right part, even in the online service manual. I ordered points for an MT250 but it was too big for the stator.I was wondering it its possible to maybe fix up the contact breaker points themselves?
Hey Kevin, great video's , do you have an Email or some way to ask you a question about my 1999 Ke100 I just got, the cylinder and head are trash( ring broke) want to replace with 80's 6 fin cyl. and head ???
33:30 OMG that points/condenser test is gold. First thing im gonna do tomorrow is that test. Followed by the coil test I saw in your other video. Thank you for making these vids man. Will post an update if I can get her running. (Fingers crossed!) Any tips on how to fix a snapped off spark plug wire on a coil? Thats my next challenge probably ha
An apple for my favorit teatcher. I have a couple of questions if I may. Do I need to have the battery conected to make a - 81 Suzuki ts 100/125 er motor to ignite? Where do I ground the coil if I don't? And, is it important to use the right spark plug cap with the resistor and all ?
Hi Kevin Thank you for the video it breaks down for us electroinicly challenged But I still have a issue with my ignition system ( no spark) Stator plate is from 63 Honda C105 with a one charging coil one lighting coil , points and a condenser, and even points are open I still get continuity beep . I un soder the 3 wires at the condenser and test individually points are operating good when it is open no continuity , when I add the condenser in to the loop still good when it is close beep when it is open no beep but when I connect the charging coil in , when the points are open still beeps always continuity . Coil tested fine wiring is only 1.5 ohm has continuity between the leads . but I can't get any spark like you showed in this video when I spin the magneto please help Thanks
OK so the test at 31:00 works, but the spark through the ignition coil is only about the same. I dont think it's strong enough to fire through the spark plug gap, but if i touch the spark plugs electrode directly to the engine it gives that weak spark too. bad source coil? bad condenser?
Hey keven ! I have a ke100(g4tr) 1974 and cant get any spark.. unfortunately i found the lead to the condenser broken so i welded it back on but now i get a ground on the points even when the points do not touch.. my guess would be to change both points and condenser..?
so I got a dt100 magneto I'm trying to wire up, the coil on the stator is wired to the lighting coils on one end, will that test ~31:00 work with the lighting leads (green and yellow) not connected to anything or do they need to be grounded? i tried testing the ignition coil on a bench today with a 6v battery like I saw in another of your videos, and got one good spark but couldn't reproduce it
Been working on a kawasaki g3tra no spark issue. Running NGK br8hs plugs and they lose spark after 15 sec running time. New plug and I'm back in business. I'm I using right plug for this set up. And if so why am I fouling so soon?
@@2strokeguru At about 37:05 you mention converting most of your bikes to CDI. Very curious how you do this. I assumed, perhaps wrongfully so, you used a kit. Great videos, BTW.
@@2strokeguru Interesting.... Would not have thought wiring would be the same as I recall Dale Sweger making an entirely new stator plate in one of his projects.Hoping these CDI boxes hold up long term for your bikes and my 44+ year Suzukis. Replacements are getting harder to find. There are always the 12v Vape conversion kits I suppose, but I like to keep OEM. Perhaps a CDI conversion would make a good video for you assuming you have not already done one I missed. Thanks!
