Topic: Honda CRF Bikes

[grcamna2]

Up on the table and had a good look today. Nice to work on something different. Nothing appears to be missing, except the throttle grip. “Borrowed” the battery from the CRF230F and it cranks nicely, once I figured out the clutch lever safety switch. The engine and gearbox are full of fresh clean oil and we have a spark. I’m going to check valve clearances next, before adding fuel.

Pulled off a few panels and fork guards. The forks aren’t  soaked, but they are “damp”.  Seals, dust seals, and fresh oil before long. So far seals, battery, grips, pads, and oil filters are all available on Amazon for next day at very reasonable prices. Amazing.

USD forks  I never had any of them open.
I imagine they ride Nice !
I wonder if they need a special tool to work on them ?

[Kevin D]

12+ inches of front fork travel
16 position adjustable compression and rebound damping
How many grandkids are gonna ride this?
I think You’re gonna learn a lot John.

[BenelliSEI]

12+ inches of front fork travel
16 position adjustable compression and rebound damping
How many grandkids are gonna ride this?
I think You’re gonna learn a lot John.

Bill….. Yes some big wrenches for the top caps. About 50mm.

Kevin….. Chris’s son is going on longer and longer “adventures” with the CRF230F. Building this one so either he or I can tag along!

[BenelliSEI]

Set it up with a fresh battery yesterday and despite cranking nicely, NO SPARK. David had suggested he had it running ages ago, which I doubt. He included a new plug cap/coil unit that I swapped in with no success. Lots of “black boxes” on this bike, so I’ll start checking connectors and continuity next. This could be painful.

[seanbarney41]

First check is the kill button...unplug it at the harness

[Stev-o]

Congrats, always fun getting a new toy.   Confused, you had spark and then no spark?

[BenelliSEI]

Congrats, always fun getting a new toy.   Confused, you had spark and then no spark?

Steve….. I should have written “He had spark”. David said he ran it. Now I find that strange as I crank and see no spark. Got frustrated late yesterday, will have a fresh look today.

[Stev-o]

Congrats, always fun getting a new toy.   Confused, you had spark and then no spark?

Steve….. I should have written “He had spark”. David said he ran it.

Got it.  Personally, I NEVER believe a seller...

[MauiK3]

Bad coil?

[grcamna2]

Congrats, always fun getting a new toy.   Confused, you had spark and then no spark?

Steve….. I should have written “He had spark”. David said he ran it. Now I find that strange as I crank and see no spark. Got frustrated late yesterday, will have a fresh look today.

Clutch or kickstand safety switch ?

[BenelliSEI]

I jumped those out and nothing doing…..

[grcamna2]

I jumped those out and nothing doing…..

I hope it's a continuity issue,rather than an expensive part.

[BenelliSEI]

I jumped those out and nothing doing…..

I hope it's a continuity issue,rather than an expensive part.

I’m a bit out of my comfort zone. “Static resistance checks for the stator and pulse generator” next time I’m in the shop.

[BenelliSEI]

Getting frustrated! All the electrical components test as “OK”. Beginning to suspect the engine control box or the throttle position instrument. If I could convert this to a set of standard points, I would!

[grcamna2]

Getting frustrated! All the electrical components test as “OK”. Beginning to suspect the engine control box or the throttle position instrument. If I could convert this to a set of standard points, I would!

How much do they want for good,used ones ?

[BenelliSEI]

Getting frustrated! All the electrical components test as “OK”. Beginning to suspect the engine control box or the throttle position instrument. If I could convert this to a set of standard points, I would!

How much do they want for good,used ones ?

There’s a guy not far away that has two control boxes for $60 each, so not too bad. Tim (the fellow I race the LEXUS with) is a factory trained FORD mechanic and a real electronics wizard. I sent him a note inviting him (and his testing gear) over for a beer! I’ll start ordering bits after I hear what he concludes. I’m normally not this clueless but this one has me stumped.

[grcamna2]

Getting frustrated! All the electrical components test as “OK”. Beginning to suspect the engine control box or the throttle position instrument. If I could convert this to a set of standard points, I would!

How much do they want for good,used ones ?

There’s a guy not far away that has two control boxes for $60 each, so not too bad. Tim (the fellow I race the LEXUS with) is a factory trained FORD mechanic and a real electronics wizard. I sent him a note inviting him (and his testing gear) over for a beer! I’ll start ordering bits after I hear what he concludes. I’m normally not this clueless but this one has me stumped.

I'm interested to find out what it is.
Does the start button turn the engine over and all the other things work:just no spark ?

[BenelliSEI]

I’ve jumpered out the clutch safety switch (no neutral switch) and dismantled the kill switch to make sure there are no internal faults. The starter button works as it should. The minimalist head and tail light are wired to only come on when the engine is running (no switch) so there is nothing else. I’ve confirmed grounds and power in every spot that should have them. Resistance tests for the stator and igniter are within spec. Tried three different coil/ spark caps. Mmmmm.?

[grcamna2]

I’ve jumpered out the clutch safety switch (no neutral switch) and dismantled the kill switch to make sure there are no internal faults. The starter button works as it should. The minimalist head and tail light are wired to only come on when the engine is running (no switch) so there is nothing else. I’ve confirmed grounds and power in every spot that should have them. Resistance tests for the stator and igniter are within spec. Tried three different coil/ spark caps. Mmmmm.?

You checked all the ground connections,plus the stator ground;would it help to scrape some frame paint off of a lower engine mount bolt/spacer.
Does the engine case need to Ground/earth to the frame to make a connection ?

[BenelliSEI]

Rectifier and engine have seperate grounds. Cleaned and reattached. Today I also jumped in a full size battery to ensure there are no low voltage conditions….. NO SPARK. Next I need to figure out a way to test the “ignition pulse generator” while cranking over the engine. I did the “resistance check” to this unit and it checked out perfectly, but maybe it’s not being triggered with each rotation? I can’t find an air gap spec for this unit, but maybe it’s filthy or

[grcamna2]

Rectifier and engine have seperate grounds. Cleaned and reattached. Today I also jumped in a full size battery to ensure there are no low voltage conditions….. NO SPARK. Next I need to figure out a way to test the “ignition pulse generator” while cranking over the engine. I did the “resistance check” to this unit and it checked out perfectly, but maybe it’s not being triggered with each rotation? I can’t find an air gap spec for this unit, but maybe it’s filthy or

Good idea on the pulse generator;to see if it's pulsing.
You considering getting ($60) a good Igniter,as it's most likely that.
You've looked at all the other things.

[BenelliSEI]

Tested everything with Tim today. Pulse generator, stator, coil, throttle position sensor, and starter solenoid are all working as they should. Ultimately the ignition control unit (sealed black box) appears to have no outputs…..

Honda part number 30410-KSK-711 appears as NLA in most places although CMSNL shows one for US$641.00! Yikes. Found an EBay vendor with knock offs for 1/2 that (with excellent feedback from other buyers). Fingers crossed, order sent. Bike is useless with no spark.

[grcamna2]

Tested everything with Tim today. Pulse generator, stator, coil, throttle position sensor, and starter solenoid are all working as they should. Ultimately the ignition control unit (sealed black box) appears to have no outputs…..

Honda part number 30410-KSK-711 appears as NLA in most places although CMSNL shows one for US$641.00! Yikes. Found an EBay vendor with knock offs for 1/2 that (with excellent feedback from other buyers). Fingers crossed, order sent. Bike is useless with no spark.

John,good to know exactly that it's the Black Box;with 'the process of elimination',you went-about it correctly.
I imagine the "guy not far away" who has the two Black Boxes for $60ea. for a CRF250 aren't the same part#?
A good,used one from another source may show itself,after more searching.