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General Category >> Rubber Side Down! >> No Spark/ low voltage going to spark plug
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Message started by stepanfez on 07/24/14 at 11:05:03

Title: No Spark/ low voltage going to spark plug
Post by stepanfez on 07/24/14 at 11:05:03

Hi!

I got my '87 savage couple months ago and seem to be going over the same problem the whole time. Currently I can't witness any visible spark. There is only about 2-3 Volts going to the plug while pushing the starter button.

Things I have done: new spark plug(s), new pick-up coil, new ignition coil, new battery, replaced spark cap, looked for shorts and corroded connections (no 100% sure there), inspected the kill switch etc.

There is steady 11-12V going to the primary coil, so I suspect faulty CDI. Is it even possible? In the past, I had occasional misfires and fouled spark plug due to carbon build-up. Thanks for all your wisdom on this. Other than that, it is a great machine, however it stresses me the **** out, not being able to ride.

Thanks for help!

Stepan

Title: Re: No Spark/ low voltage going to spark plug
Post by verslagen1 on 07/24/14 at 11:42:23

It's possible the TDI(aka CDI) is burnt out.
there's a power chip that goes if the key is left on too long.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1293638302/0

Title: Re: No Spark/ low voltage going to spark plug
Post by stepanfez on 08/20/14 at 06:45:23

I suspected that too, so I replaced it with another (used) one.
The bike acted the same way, as with the old one, so currently I am probably a proud owner of 2 functional TCI units :)

Title: Ignition problem
Post by stepanfez on 08/19/14 at 14:18:02

Howdy,

I've been going over the issue of weak and intermittent spark on my '87 and its driving me nuts. Over the time I managed to replace almost every single component of the ignition circuit. Only problem which I've discovered is a probably faulty starter relay. I am reading a 4V drop on the relay terminal connecting starter motor and ignitor. Is there any chance that this relay can affect the bike's ignition while in motion?

Any suggestions and hints on this one will be appreciated.
YOU WILL FIND ALL THE DETAILS IN THE PICTURE ATTACHED.

Thanks for your experience,
Steve

Title: Re: Ignition problem
Post by Spamy on 08/19/14 at 14:52:21

If the relay is not engaged I would expect to see no voltage on the starter side of the relay. Are you measuring to ground for these indicated readings?

I would be tempted to start the bike and then remove the relay wires in question, to see if your spark is better.

What is giving you a reason to suspect a weak spark?

Title: Re: Ignition problem
Post by stepanfez on 08/20/14 at 05:52:56

I will give it a try, once I get to the bike.

At first I thought I am having a typical rich mixture problem, as the spark plug kept getting fouled with black carbon layer, the bike was running rough once it was warm, it stalled and backfired. After I eliminated the carb by multiple cleanups, checks and rejetting, I was drawn to the mysterious dark side of the electrical system. The last thing, that I changed was the ignition coil, after which I took the bike for a ride and got about 150km without a problem. However when I stopped for about an hour, the bike wouldn't fire up. Checked for spark/Nothing...

Title: Re: Ignition problem
Post by Dave on 08/20/14 at 06:05:54

Have you tried bypassing the kick stand safety switch? Those can be finicky at times, and can keep the bike from running when they go bad. It is possible that one could cause some intermittent problems.

Dave

Title: Re: Ignition problem
Post by stepanfez on 08/20/14 at 06:34:07

Thanks for tip.. I never paid too much attention to it, as the side-stand light worked properly. Do you thing that the Side-stand interlock could be causing this mess? I suppose 1987 should have one..thinking about it, I never tried to put in gear with the side-stand down. I guess the bike should die (with properly working interlock), right? Any idea where is this unit located? I am pretty sure it's not under the seat as Clymer describes.

Steve

Title: Re: Ignition problem
Post by stepanfez on 08/20/14 at 06:37:03

sorry I meant the side-stand relay..

Title: Re: Ignition problem
Post by Dave on 08/20/14 at 06:56:27

Here is a thread that shows where stuff is/goes.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=tech;action=display;num=1099317926

Title: Re: Ignition problem
Post by stepanfez on 08/20/14 at 07:06:10

I see.. and yeah the interlock system was probably by-passed by the previous owner, along with the clutch switch. I don't have the bike at home to check, but will soon.