No spark on Dakar 200 GY

B-Dog · 04-30-2010, 09:45 AM

Just got a used bike from a friend that hasn't been used in about 5 years. It was out in the weather part of the time but was running when it was parked. I can't get a spark out of the spark plug. Does anyone know where I can get a decent wiring diagram?

I cleaned all of the plug connections. All of the lights work. There are 2 wires coming out of the clutch lever housing on the handle bar.. Is that so it has to be in neutral or either the clutch lever squeezed when in gear before it will start; a safety thing?

Any suggestions as to what may be the problem would be greatly appreciated. This is the first bike of any type I have ever owned.

Weldangrind · 04-30-2010, 11:31 AM

Welcome!

I'll wait for the dual sport guys to chime in, but I will say that I've heard about the clutch safety switch before. Have you bought a new NGK plug?

katoranger · 04-30-2010, 12:42 PM

The clutch lever needs to be squeazed or the bike in neutral to start. My switch failed so I just crimped the wires together.

My bet is on a cdi unit or the connection there.

Allen

B-Dog · 04-30-2010, 02:23 PM

I got a new Autolite spark plug that is supposed to be a cross reference to the original.

I thought maybe the CDI as well. I'll probably order one and try it. They are not that expensive. Found one here,

http://www.motopartsmax.com/index.ph...roducts_id/504

Thanks for the feedback. I'll let you know what I find when it's fixed.

FastDoc · 04-30-2010, 02:35 PM

CDI failures are probably the most common issue here. Also pinched wires where they come out of the stator cover and by the countershaft sprocket.

B-Dog · 04-30-2010, 02:52 PM

That's very interesting because I found that the yellow wire has a nick in it that took a little bit of the insulation off and it may have shorted to the casing. It doesn't look like its broken and it isn't shorting to the casing now as far as I can tell, with the cover off and pulled away. I'll have to seal it up with some RTV or something before I put the cover back on. I can't believe the design here.

If it did short to the casing, could it have taken out the CDI?

FastDoc · 04-30-2010, 04:02 PM

I can picture it killing the CDI. CDI's are cheap. Think of them like keeping a spare light bulb for replacement.

B-Dog · 05-10-2010, 03:11 PM

New CDI fixed the problem. Hopefully put the carburetor back on tonight and fire it up. Thanks to everyone for the info!

FastDoc · 05-10-2010, 03:52 PM

Quote:

Originally Posted by B-Dog

New CDI fixed the problem. Hopefully put the carburetor back on tonight and fire it up. Thanks to everyone for the info!

Good news. Thanks for the feedback. That helps the next guy too!

katoranger · 05-10-2010, 06:51 PM

Good news. Now you need to order a spare one.

Allen

phil · 05-10-2010, 08:47 PM

We need some pics of the bike, apollo used their engine on the 150 i thought it is one of the better running engines i have seen

B-Dog · 05-26-2010, 04:31 PM

Ended putting a new carburetor on as well and it fired right up. Runs great. I'll get a picture posted. Nothing really special looking about it as far as I can tell.

Oh, also took off the old clumsy air filter housing with foam cartridge inside and put on a new cone type directly connected type. That really freed up a lot of space.

SpudRider · 05-26-2010, 05:07 PM

Welcome to these forums! I am glad you got your bike running.

The Chinese CDI units are getting notorious for their failures. :( I agree with the others; I keep a spare CDI unit on hand.

When you get time, please do post some photos of your bike.

Spud

katoranger · 05-26-2010, 11:28 PM

Well, I just replaced CDI on a honda xr. It was running and then quit. So its not just china bikes.

Allen

SpudRider · 05-27-2010, 03:02 AM

Quote:

Originally Posted by katoranger

Well, I just replaced CDI on a honda xr. It was running and then quit. So its not just china bikes.

Allen

Indeed, the CDI units also fail on the Japanese bikes.

However, the Japanese CDI units can cost $120, instead of $20! 8O

Spud

04-30-2010, 09:45 AM	#1
B-Dog Join Date: Apr 2010 Location: Florida Posts: 8	No spark on Dakar 200 GY Just got a used bike from a friend that hasn't been used in about 5 years. It was out in the weather part of the time but was running when it was parked. I can't get a spark out of the spark plug. Does anyone know where I can get a decent wiring diagram? I cleaned all of the plug connections. All of the lights work. There are 2 wires coming out of the clutch lever housing on the handle bar.. Is that so it has to be in neutral or either the clutch lever squeezed when in gear before it will start; a safety thing? Any suggestions as to what may be the problem would be greatly appreciated. This is the first bike of any type I have ever owned.
	0

04-30-2010, 11:31 AM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Welcome! I'll wait for the dual sport guys to chime in, but I will say that I've heard about the clutch safety switch before. Have you bought a new NGK plug? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

04-30-2010, 12:42 PM	#3
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	The clutch lever needs to be squeazed or the bike in neutral to start. My switch failed so I just crimped the wires together. My bet is on a cdi unit or the connection there. Allen __________________ You meet the nicest people on a Honda Clone.
	0

04-30-2010, 02:35 PM	#5
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	CDI failures are probably the most common issue here. Also pinched wires where they come out of the stator cover and by the countershaft sprocket. __________________ Happy to serve.
	0

04-30-2010, 04:02 PM	#7
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I can picture it killing the CDI. CDI's are cheap. Think of them like keeping a spare light bulb for replacement. __________________ Happy to serve.
	0

04-30-2010, 02:23 PM	#4
B-Dog Join Date: Apr 2010 Location: Florida Posts: 8	I got a new Autolite spark plug that is supposed to be a cross reference to the original. I thought maybe the CDI as well. I'll probably order one and try it. They are not that expensive. Found one here, http://www.motopartsmax.com/index.ph...roducts_id/504 Thanks for the feedback. I'll let you know what I find when it's fixed.
	0

04-30-2010, 02:52 PM	#6
B-Dog Join Date: Apr 2010 Location: Florida Posts: 8	That's very interesting because I found that the yellow wire has a nick in it that took a little bit of the insulation off and it may have shorted to the casing. It doesn't look like its broken and it isn't shorting to the casing now as far as I can tell, with the cover off and pulled away. I'll have to seal it up with some RTV or something before I put the cover back on. I can't believe the design here. If it did short to the casing, could it have taken out the CDI?
	0

05-10-2010, 03:11 PM	#8
B-Dog Join Date: Apr 2010 Location: Florida Posts: 8	New CDI fixed the problem. Hopefully put the carburetor back on tonight and fire it up. Thanks to everyone for the info!
	0

05-10-2010, 06:51 PM	#10
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Good news. Now you need to order a spare one. Allen __________________ You meet the nicest people on a Honda Clone.
	0

05-10-2010, 08:47 PM	#11
phil Join Date: Jun 2008 Location: wise va Posts: 636	We need some pics of the bike, apollo used their engine on the 150 i thought it is one of the better running engines i have seen __________________ halls auto l coolster, modcycles, yanmar & zongshen, dealer fired roketa,lifan and jet moto and apollo quit me who's next
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05-26-2010, 04:31 PM	#12
B-Dog Join Date: Apr 2010 Location: Florida Posts: 8	Ended putting a new carburetor on as well and it fired right up. Runs great. I'll get a picture posted. Nothing really special looking about it as far as I can tell. Oh, also took off the old clumsy air filter housing with foam cartridge inside and put on a new cone type directly connected type. That really freed up a lot of space.
	0

05-26-2010, 05:07 PM	#13
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Welcome to these forums! I am glad you got your bike running. The Chinese CDI units are getting notorious for their failures. :( I agree with the others; I keep a spare CDI unit on hand. When you get time, please do post some photos of your bike. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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05-26-2010, 11:28 PM	#14
katoranger Join Date: May 2007 Location: Altamont, Kansas Posts: 15,103	Well, I just replaced CDI on a honda xr. It was running and then quit. So its not just china bikes. Allen __________________ You meet the nicest people on a Honda Clone.
	0