Topic: Please help..weak spark and only when letting off starter

[crazypj]

Did you check battery voltage while cranking? (just put meter on battery and crank away  )
I used to teach people to remove lead going to starter and check output voltage from solenoid, sometimes the results are real surprising. (voltage tests are always surprising )
 I measured 318 peak volts on the 12v side of a Suzuki Intruder at about 5,000rpm    (you need a peak voltage adapter for meter)

[grcamna2]

+1 on what wrenchmuch said...& make sure the coils are the correct impedance(ohms) for your application along w/ the correct plug caps;also your right handlebar switch starter button contacts may need to be cleaned.

[crazypj]

Bar contacts are either working or not working, if solenoid clicks, starter button is working and supplying enough voltage to operate.The solenoid internal contacts may be burned, there is a plastic stopper inside which limits movement and causes the 'click' when it bottoms/tops out.
Thats why I said to check battery voltage when cranking, plus, check output voltage to starter with lead disconnected (I would also do a load test to starter, should be around 40~50 amps draw)

[Spanner 1]

PJ....... he already changed-out the solenoid with the same results. The bike will crank the starter fast when the solenoid terminals are shorted. It's not the solenoid, it's those 1 or 2 ohm coils hogging loads of amperage as soon as you turn the key on and leaving nothing for the starter..... makes sense to me !.....by shorting the solenoid your 'taking back' the power from the coils and sending it to the starter........ install 5 ohm coils, problem gone.

[josephus]

sounds to me wiring try running the solid black wire to power the coils instead of the black and white one . caution engine stop button may not work. also for a more powerful spark get some old vw plug wire caps and put on as they have no resisstors in them like the factory honda ones do. if you have an old one pop it apart the resistor looks like a round fuse.

[crazypj]

PJ....... he already changed-out the solenoid with the same results. The bike will crank the starter fast when the solenoid terminals are shorted. It's not the solenoid, it's those 1 or 2 ohm coils hogging loads of amperage as soon as you turn the key on and leaving nothing for the starter..... makes sense to me !.....by shorting the solenoid your 'taking back' the power from the coils and sending it to the starter........ install 5 ohm coils, problem gone.

 I guess I miss-read something?
There is less resistance to solenoid, starter 'robs' power from coils, not the other way round.
Is it a 'new' new solenoid or just 'new' to the bike?
 There is no harm in doing the tests I suggested, in fact it proves if solenoid is good or bad.
 Even new parts can be faulty 'out of the box' (unusual but it happens)
 As we are not 'there' to 'see' exactly whats going on, we need to eliminate variables
It could be the new battery, has it been load tested yet?
 It may well be wrong coils, wrong leads, wiring completely messed up and various things connected wrong.
 It is a real simple circuit, no 'computers' controlling anything so it should be simple to fix
 I'm bored with this thread now and really don't want to argue with people trying to help OP

[Spanner 1]

I'm bored with it too ... especially since the OP hasn't bothered to come back to his own thread since Dec. 8th.!!!!

[TwoTired]

I'm bored with this thread now and really don't want to argue with people trying to help OP

That is the way of the new "modern" forum, it seems.   Facts and logical science be damned, "looks" and what "feels" right is vogue.

[josephus]

let me know how the  witching the wire goes if i am wrong i am wrong but if im right it should fire up

[crazypj]

Hi TT,
 As Spanner 1 noted, OP hasn't been back to give any feedback, thread is now just a discussion about what and where to check

[AndyJ]

Hey guys,
Thanks for all of the input and advice, I realize I haven't visited the forums in sometime.  Been having issues in other areas which seemed to be of greater importance, like getting the bike to actually run.  I will certainly check into the starter and wiring when time permits.  Just kicking it for now...
It's been a challenge juggling my two young boys and and working full time. Progress on the bike has been slow.  The knowledge I've learned here is invaluable and appreciated.
Still have a lot of plans for the bike, and cannot wait to complete.
Warest Regards from FL,
Andy

[Spanner 1]

Andy... it's all good!... thanks for posting and very best of luck with your life issues, that's life iddinit ?
Ask a new Q any time your ready, good luck 

[wrenchmuch]

Andy
Electrical issues will often keep the bike from running . When troubleshooting start with spark first then move to fuel . Electrical issues will often masquerade as fuel issues ( for instance a weak spark can make your plugs look like the fuel mix is rich) .
Good luck

[Rigid]

Want to test your battery in real world conditions and know exactly what it is doing in YOUR bike?  Charge it overnight, push the start button to engage the starter with a voltmeter attached to the battery terminals.  If it drops below 11 volts under load, the battery cannot deliver enough amperage and is faulty.  Another issue that is less likely is the starter is drawing excessive amperage due to internal failure or external overload.  Rock on.