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  1. #1

    99 SLH - Suddenly no spark

    Put a rebuilt engine in a couple of months ago. Got a new AGM battery and it shows >11v cranking. It has been running fine up until a few days ago. Went out to ride and would not start, cranking strong, but no start. Put a spark tester between plug and plug wire...... no spark.

    1. MFD is not working - missing digits and now the red light flashes all the time. Removed MFD fuse and unplugged MFD. Last night I reconnected MFD but kept fuse out

    2. I disconnected Yellow/black wires in box.

    3. Sometimes it comes back to life without warning and starts, wish I could say I fixed it but this morning no spark. I did the Red/Purple to Orange jumper but it has no effect on this issue. Got it running last night and really can't explain why it suddenly started. I did charge the battery earlier in the day but it did not start right away with the fresh charge and cranking voltage was >11v

    4. I get 0 volts from CDI brown wire.

    5. Black to purple 796 ohms manual says I should get 1200



    K447 I have read your stuff regarding the electrical system and troubleshooting. Not sure what to do next.

    Like I said, sometimes it just comes back to life and runs fine.
    Last edited by tjruberg; 09-05-2014 at 12:54 PM.


  2. #2
    OK, out trying it again. I happen to push the bilge pump switch and got nothing from the bilge pump. Wiggled the bilge wires connected to the bilge pump and now bilge pump works.

    Now I try to start it up and still no spark. I remember something about the LR module (voltage regulator?) and disconnecting it then try starting while pushing the bilge switch.

    Sure enough, when I push the bilge pump switch the engine starts right up.

    I do not have anything disconnected in the electrical box. So do I have a bad LR module?

    I only get voltage to the orange terminals when I push the bilge switch

    is it 14 - REG.RECT/CUTOFF,LR31 4010302 ?
    Last edited by tjruberg; 09-05-2014 at 02:29 PM.

  3. #3
    Click avatar for tech links/info, donation request K447's Avatar
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    Leave MFD disconnected at rear connector if it is not working properly.

    LR module is supposed to switch on battery power to Orange wire when engine is cranking or running. The Bilge button overrides this and simply forces full battery voltage onto Orange wires.

    Measure the voltage on Orange. Without pressing Bilge button the voltage should be very close to zero. Press Bilge button, voltage should jump up to full battery voltage. Release Bilge button and crank engine. Voltage on Orange should again jump up to battery voltage. If it does not, the LR module is bad or it is not connected properly.

    The LR module needs a solid ground connection (Black wire or metal tab on LR module), a connection to Yellow, connection to Red/Purple. And of course the Orange wire output to Orange terminals.

    When engine is not running the LR module should have battery voltage on Red/Purple and on Yellow.
    Last edited by K447; 09-05-2014 at 05:43 PM.

  4. #4
    K447,

    I only get voltage on the orange when the bilge is push.

    When engine is not running the LR module should have battery voltage on Red/Pule and on Yellow
    - I will try this now

    Thanks for the help. This all just started in the last few weeks. Odd thing is, sometimes it starts.

  5. #5
    I disconnected the Orange, Red/purple and Yellow wires from the LR

    Orange = 8.6 volts
    Red/Purple = 11.19
    Yellow = 12

    I tested the Red/Purple posts that have the remaining Red/Purple wires and it is 12 volts

    The actual Red/Purple wire from the LR only shows 11.19v

  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by tjruberg View Post
    I disconnected the Orange, Red/purple and Yellow wires from the LR

    Orange = 8.6 volts
    Red/Purple = 11.19
    Yellow = 12

    I tested the Red/Purple posts that have the remaining Red/Purple wires and it is 12 volts

    The actual Red/Purple wire from the LR only shows 11.19v
    If you disconnected the LR module (from the terminal board, I presume) then where are you measuring the voltages?

    Red/Purple feeds voltage TO the LR module. Same with Yellow. The only output on the LR module is Orange.

    Where are you putting the black meter probe while you are doing these measurements?

  7. #7
    Sorry for the confusion. If I leave the LR module connected and test the Red/Purple, Yellow, Orange I get

    Red/Purple = 12.47v
    Yellow = 12.47v
    Orange (only when bilge button pushed, cranking or not cranking) = 12.47

    Black test lead on battery neg or engine block

  8. #8
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by tjruberg View Post
    Sorry for the confusion. If I leave the LR module connected and test the Red/Purple, Yellow, Orange I get

    Red/Purple = 12.47v
    Yellow = 12.47v
    Orange (only when bilge button pushed, cranking or not cranking) = 12.47

    Black test lead on battery neg or engine block
    Orange has weak or no voltage when engine is cranking, unless Bilge button is pressed, correct?

    If so, LR module is no good.

  9. #9
    Quote Originally Posted by K447 View Post
    Quote Originally Posted by tjruberg View Post
    Sorry for the confusion. If I leave the LR module connected and test the Red/Purple, Yellow, Orange I get

    Red/Purple = 12.47v
    Yellow = 12.47v
    Orange (only when bilge button pushed, cranking or not cranking) = 12.47

    Black test lead on battery neg or engine block
    Orange has weak or no voltage when engine is cranking, unless Bilge button is pressed, correct?

    If so, LR module is no good.
    Yes, nothing on orange unless I push the bilge switch. I'll get a new LR module.

    Thanks again for the help.

    tj

  10. #10
    Frustrated!

    Got a new LR Module from SBT (OEM #4010302 SBT #15-301) and it is bigger than the original. It installed OK but STILL no spark unless I push the bilge pump switch.

    Can I test the yellow wire from the stator to make sure it is sending the RPM signal to the LR module? When I'm cranking the engine what will the yellow from the stator do? is it sending volts out?

    What do I do next ????

    Update: Ohm test

    1. Black to Purple = 800 ohms
    2. Red/Purple to Yellow = 1.4 ohms
    3. Black to Gray = 88 ohms
    Last edited by tjruberg; 09-12-2014 at 10:02 PM.

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