Zong Sierra No Spark...what am I missing?

[ManOfActionDT]

Ah the joys of having a life and family... aka the reason the Zong only gets attention twice a year.

Aside from a new wiring harness, relay, and flywheel I have replaced all of the other parts of the electrical system on my Sierra... I have good news and bad news... the good news... I'm getting voltage to the spark plug... the bad news it's only 12 volts.... time to find the spare CDI boxes...

I will get the current resistance values and post them. One bit of advice, what is the best way to make sure the left crank case cover is lined up correctly? As I was putting mine back on it feels like magneto is pulling it askew as it goes on.

[ManOfActionDT]

Electrical System Resistance Values

Spark plug cap resistance:
Both Yamaha manuals specify 10K Ohms =10.3k

Ignition coil resistance:
Primary Coil: 0.56 to 0.84 Ohms = .7
Secondary Coil: 5.68K to 8.52K Ohms = 6.35k

Pickup/Pulse Coil Resistance:
Both Yamaha manuals specify 656 to 984 Ohms = 747

Exciter/Charge Coil Resistance:
Yamaha XT225 Manual specifies 584 to 876 Ohms = 646

[SpudRider]

All of your electrical resistance values look good. Indeed, it is time to try one of the spare CDI units.

There is no trick to installing the left crankcase cover. Just ease it on as straight as you can, and align the bolt holes. However, be careful not to pinch the wires coming from the stator and pickup coils.

[ManOfActionDT]

How many volts should be coming out of the trigger coil? stator? wire to the ignition coil? Are they all 12v? or should they be higher?

[SpudRider]

Originally Posted by ManOfActionDT

How many volts should be coming out of the trigger coil? stator? wire to the ignition coil? Are they all 12v? or should they be higher?

The trigger/pickup coil sends very short spurts of voltage to the CDI unit, so I don't think Yamaha specifies any voltage/current figures. Likewise, I don't know of any specific test voltage for the stator. To the best of my knowledge, Yamaha only specifies resistance values for testing the electrical components.

All your resistance test values look good. I'm betting you have a bad CDI unit.

[ManOfActionDT]

I've tried 3 cdi boxes.... checked every electrical connection on the bike for continuity.... still no spark... getting 40 VAC from charging coil / ignitor / signal coil, 12.8 VDC from regulator, .....Anyone know of a shop in the Seattle area that works on Zongs? Still no spark !?!

[SpudRider]

Perhaps you can find a Yamaha shop which will work on your Zong.

[ManOfActionDT]

On the wiring diagram I downloaded there are three yellow wires going to the rectifier and a red and ground leaving... the rectifier on my bike has three yellow going in and a red, green, and black leaving? do I have the wrong rectifier?

[SpudRider]

Originally Posted by ManOfActionDT

On the wiring diagram I downloaded there are three yellow wires going to the rectifier and a red and ground leaving... the rectifier on my bike has three yellow going in and a red, green, and black leaving? do I have the wrong rectifier?

Does your Zongshen regulator/rectifier look like mine in the photograph below?

[ManOfActionDT]

Yes that looks like my rectifier, where do each of the out wires connect to? I'm beginning to suspect there is something up with my flywheel / starter clutch. I went back and measured the voltage out of a the original and new rectifiers and it's only putting out 4 to 6 volts. I found some where that there should be approx 40 VAC coming out of the stator coil I'm getting a peak of 17 randomly, and since the stator and signal coils are both brand new I have to wonder if something with the flywheel is amiss... know of anyone that has had issues?

[ManOfActionDT]

In the photo there are two connectors in the upper left hand corner, what are those for? I don't have anything like that on my bike.

[ManOfActionDT]

I have a new flywheel and wiring harness on the way from TaoBao (Chinese for cheaper and faster to my door than an American Yamaha shop).... if that doesn't fix it.... I'm about ready to part it out and put the money toward a new crf250l.....

[SpudRider]

Originally Posted by ManOfActionDT

Yes that looks like my rectifier, where do each of the out wires connect to? I'm beginning to suspect there is something up with my flywheel / starter clutch. I went back and measured the voltage out of a the original and new rectifiers and it's only putting out 4 to 6 volts. I found some where that there should be approx 40 VAC coming out of the stator coil I'm getting a peak of 17 randomly, and since the stator and signal coils are both brand new I have to wonder if something with the flywheel is amiss... know of anyone that has had issues?

The three yellow wires come from the stator. The Red wire goes to the positive terminal of the battery, and the green wires go to ground.

I doubt very much much your flywheel is bad. My Zong has an excellent, Yamaha XT225 flywheel, and it has never caused me any problems. Indeed, I have never heard of anyone having XT225 flywheel problems, or TW200 flywheel problems either, for that matter.

[SpudRider]

Originally Posted by ManOfActionDT

In the photo there are two connectors in the upper left hand corner, what are those for? I don't have anything like that on my bike.

The 3 yellow wires from the stator are inserted into a molex connector, which mates to another molex connector leading to the regulator/rectifier (R/R). The red wire and two green wires coming from the R/R are inserted into a molex connector, which connects to the battery and electrical grounds.

[SpudRider]

Originally Posted by ManOfActionDT

I have a new flywheel and wiring harness on the way from TaoBao (Chinese for cheaper and faster to my door than an American Yamaha shop).... if that doesn't fix it.... I'm about ready to part it out and put the money toward a new crf250l.....

I seriously doubt the flywheel is the problem. However, since you have already ordered it, you might as well give it a try.

If you want to remove the flywheel, you are going to need a flywheel holder and a flywheel puller. I suggest you get a flywheel puller for the Yamaha TW200, and a generic flywheel holder from eBay.

http://www.bikebandit.com/motion-pro...FY17fgodeAYA8w

http://www.ebay.com/itm/PIT-POSSE-FL...669fb7&vxp=mtr