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I have 2002 road star midnight. I lost completely spark on all 4 spark plugs. Before bike was running OK but sometimes on low RPM while idling would skip a firing on a at least one cylinder making spufff like sound. I put new spark plugs, and wiggled a little coil wires. Bike with new spurk plugs would not fire up at all. Checked for spark on all 4 spark plugs - no spark., not even an electrical I lost completely spark on all 4 spark plugs. Before bike was running OK but sometimes on low RPM while idling would skip a firing on a at least one cylinder making spufff like sound. I put new spark plugs, and wiggled a little coil wires. Bike with new spark plugs would not fire up at all. Checked for spark on all 4 spark plugs - no spark., not even an electrical charge going to spark plug. Went back to coils. Each coil (there 2 of them) has 2 spark plug wires and 2 ignition timing signal wires connected to them. I realized that these ignition timing wires contacts are corroded to the point they would not conduct a charge from the distributor to coil. CLEAN ALL THE TIMING WIRES Contacts on the coils. I did that and bike fired up right away and started running much better without sputtering or skipping a cylinder firing. SO DISCONNECT ALL THE COIL WIRES AND BRUSH THE CONTACTS WITH A SMALL METAL WIRE BRUSH.
you need a bit more lead
quick get you out of trouble gadget
get a lead pencil and go over all the electrical connections
including your spark plug
then check your cdi, cdi pick up, coil, lead and spark plug
the coil lead may need cutting back about 10mm
Check the wiring on the connector plugs make sure all the wires are the same color on both sides, red to red blue to blue and so on. I had the same problem After replacing a stator and just plugging it in,after two weeks a new cdi and coil i noticed there were two wires transposed.
Sorry but they either work or they dont.
If yours isn't working, replace it.
But before you replce it consider checking the other components, because ign mods are exspensive.
it sounds like you've been already checking the other stuff. heres what i'd check if your bike came to my shop.
1. battery fully charged, and can take a load. (weak batteries = weak ign power)
i have a bike that won't fire at all with weak battery. Make sure battery is good.
2. check for spark at plugs, make sure plugs are good. Pull plugs and turn motor over.
rest plug next to head and turn over, do not touch the plug while turning over
or you can be shocked.look for spark.
if you have spark , then you ign mod is working.
if no spark, then check #3
3. power to coils. check the power going into coils,
if power but no spark, then coil is bad.
if no power. check #4
4. power to coils comes from a ignition system ( points/ cdi /ign. module)
there is a stator and a rotor. and a signal generator. on your motor
the signal generator wire sends a signal to the cdi, every time the rotor rotates.
the ignition system (ign.mod) sends power to coil.
so if no signal to the cdi, then signal generator is bad
if signal going into cdi but not sending the power to the coils then the cdi/ ign. mod is bad.
could be a bad wire or plug cap they have a resister in them, each coil fires two plugs, so if the other one works off that coil the cdi is probably ok. pull the caps off and check the resistance from the plug wire back to the coil ground, they need to be the same, the wires are moulded into the coils so if one has high or open resistance-new coil required
its possible the cdi unit has failed or the hd leads/spark caps might be at fault, i had the same problem on a 1990 zzr600 it turned out to be spark caps where ao to high a resistance and causing no spark to pass. try this first and if still no spark id go with another cdi unit. hope this helps
The voltage on the green wire must be pulsating when cranking/starting the bike, not steady. Confirm by similarly testing the voltage on the black wire on the left ignition coil. If the green still reads a constant voltage, then the CDI is faulty; to be more specific, most likely that the switching tansistor inside the CDI that drives the right ignition coil has shorted.
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