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Discussion Starter #1
Hello,

I was trying to go through a few other threads on this same issue, but I didn't want to hijack; especially when some of them are over a decade old.

Recently picked up another SV650 (Naked this time) to kill time during the lock-down, that is beating my behind trying to get to run and repair. I feel like it is going to be something simply stupid and i'm going to laugh when I find it. The main issue i'm running into right now is the no-spark issue. Here is what i've checked so far and some details to get you the background of everything right now:

  • Aftermarket LED bulbs installed, but replacing some of them; shouldn't really cause this issue.
  • Motorcycle had Stator, Rectifier / Regulator (looks like non-MOSFET unit, will replace once I get the bike running), Coils, and starter replaced by previous owner. They look like aftermarket parts (Possibly Ricks?), and was told these are all new parts.
  • Clutch switch is bypassed by previous owner. Will turn over starter with kickstand up or down, in gear or not.
  • Battery is brand-new, reading 12.9V to 13.1V; i'm also keeping it on a Battery Tender just to make sure it doesn't become the issue, keeping at peak shape.
  • Checked the ignition:
    • Getting about 100ohms on the security circuit with it in the "On" position.
      • Tried an ignition from a 2001 SV650S, getting same reading; no issues there.
    • No burnt connections or corrosion that I could see, cleaned with contact cleaner just in case.
  • Checked Fuses:
    • No blown fuses, replaced them anyhow as they're cheap and I have spares on hands.
  • Checked at the Ignitor:
    • O/R - 5.3V.
    • O/W? - 12.7V; Can revisit this if needed.
    • Tried an ignitor from another bike, same readings.
  • Checked Ground:
    • Nothing loose, terminating to the front-right bolt at the base of the 2nd cylinder. Cleaned with contact cleaner just to be sure and scrubbed any corrosion off of it.
    • Getting battery voltage (12.9V to 13.1V) measuring from this point to the positive terminal on the battery.
  • Checked Signal Pulse Generator:
    • Getting resistance within spec according to the manual.
    • Tried to check Peak Voltage, but I don't have an Oscilloscope or a Peak Voltage Adapter; did see voltage jump to 2.9 - 3.2v a few times on the DVOM. Can check again when it is not obnoxious hours, don't want to anger the neighbors.
  • Checked Ignition Coils:
    • Resistance is high but within spec., sort of.
      • 4.9 ohms in Primary.
      • No resistance change when attempting to measure secondary. Measured just the Spark Plug caps alone and am getting 8.8k ohms. Possible issue? DVOM is from HF, not calibrated to my knowledge. Getting coils mailed in next week, i'll check those to see if I get the same reading.
    • Tried to check Peak Voltage, but I don't have an Oscilloscope or a Peak Voltage Adapter. Showing battery voltage when measured from Spark Plug Cap to Ground on the battery, even while cranking on both.
    • I used brand new NGK CR8E's (non-IX, just the standard ones), and still no spark.
I should also mention the tail light and turns signals work, but the LED license plate light the past owner used is not working; not that big of a deal but just throwing that in there if it helps. I could in theory just pull the wiring harness from the 2001 SV650S, but I have a feeling that wiring harness probably has issues as well. Plus, it seems the harness might be slightly different compared to the naked harness.

TL;DR: I'm throwing out the white flag on this one, I need help. Do you all think my assessment is correct that it could be the Spark Plug wires or ignition coils causing this problem?
 

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You have done all the right tests, NONo.

By far the most common reason for no spark on the gen1 SV650 is a blown ignitor. The common cause for the blown ignitor is a failed R/R putting out too high charging voltage.

What do you mean by "No resistance change when attempting to measure secondary." ?
Does that mean the secondary measured the same as the primary, 4.9 ohms? In any case, it is rare for modern ignition coils to fail and doubly rare for both coils fail at the same time. That would be the last thing to suspect.

You said you tested an ignitor form a different bike? Are you 100% sure the other ignitor is okay, that is, have you seen it working in another SV650?
 

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Discussion Starter #3
You have done all the right tests, NONo.

By far the most common reason for no spark on the gen1 SV650 is a blown ignitor. The common cause for the blown ignitor is a failed R/R putting out too high charging voltage.

What do you mean by "No resistance change when attempting to measure secondary." ?
Does that mean the secondary measured the same as the primary, 4.9 ohms? In any case, it is rare for modern ignition coils to fail and doubly rare for both coils fail at the same time. That would be the last thing to suspect.

You said you tested an ignitor form a different bike? Are you 100% sure the other ignitor is okay, that is, have you seen it working in another SV650?
There was no change on my meter when I tried to measure secondary, but that could be my fault; I even tried removing the spark plug cap to bypass it and still had the same reading. I will have to revisit this again with the backup set.

I have seen the ignitor work on my other SV650 in the past, which has mechanical issues right now that I will address soon enough.
 

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Here is the gen1 race harness for reference. It shows the minimum circuit necessary for spark. So long as the battery is good you do not even need the Stator or Reg/Rectifier. It is pretty simple. Having access to a second SV should make it easier to find the problem as you can swap parts and compare readings. Please let us know what you find out.
53138
 

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Discussion Starter #6
So, I feel dumb. The issue was the aftermarket stator. I replaced it with a known working one and the bike has spark again. Thank you for the help all.
 
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