I bought this bike over a year ago now and still haven't gotten over 10 hours riding time from it. Mostly from my lack of knowledge on bike engines. I have done some reading and research and hopefully with a few questions answered I can get this running asap.
The bike is a 1990 Yamaha XT225 and it's pretty much sat for 4-5 months now without being started (I have turned it over every month at least though a fair bit to keep things moving around while I work out how to start it).
I have the manual, but there are some other questions which I need to find out. I'll list the testing procedure I did below.
1. Fuse - ok
2. Battery - Car Battery, 12.8V (Fully charged - I can connect this to a charger at 13v or so to test when I go to start it if it makes any difference. I found the serow didn't like to start from the motorbike battery on 12v or just above, even with the new battery.)
3. Spark Plug - Person at the bike shop gave me a DR8ES plug, I'll get a DR8EA tomorrow, however I have a bit more than a spark plug problem with this no spark issue...
4. Ignition Spark Gap - Can test that when I get the new plug and other things in order first
5. Spark Plug Cap resistance was in specification
6. Ignition Coil resistance was 0.9ohm so close enough to the resistance values listed (It's about 15C outside) (0.56-0.84 @ 20C)
"Secondary coil resistance - Plug lead to Earth = 7.34kOhms (Specification - 5.68-8.52kOhm)
7. Main Switch - Red - Brown and Black - Black/White have continuity
8. Engine Stop Switch - One wire coming off with Red and Black and Blue... is this the Start switch wiring?
9. Neutral Switch - I'm sure the neutral relay is the same Sky Blue cable... if so there is ground continuity there. Green light comes on when the main switch Red and Brown wires come on
10. Sidestand switch... where is this!?!? - Possibly the thing in my picture, see attached.
11. Neutral Relay - now I had some problems with this... I tried to get the bike started and figured the relay had an input and connected a negative to two others. I connected these three cables and it sparked a tiny bit, nothing like a massive battery spark. Then my neutral green light went out.
Now temporarily I have been crossing the Red/Brown cables to start the bike since I lost the key. When I do this the green neutral light comes on and I can push the button and start the bike. Since I zapped them wires in (11.) the green neutral light doesn't come on now...It went off as I touched them, and then I disconnected the Red/Brown cables, the battery power, and even the light/instrument<panel>. Then re-connected it and still no green light. Wonder what I screwed up there now...
12. Charge coil resistances
<Step 1> Brown and Green leads = 441ohm (Spec -> 584-876ohm)
<Step 2> Yellow - Frame ground = Didn't get a reading... connections were good and tried over a minute here and there (Spec -> 20-30ohm)
I noticed no voltage rise when I had the bike working at idle, however I have been told I had to rev it for the volts to go up. When I first got the bike if I stalled it (happed alot because of the rubbish carby) it wouldn't start again (yes this sucked in the middle of nowhere, a few times... once I pushed it through about 2km of boggy sand, took me a couple hours). I replaced the battery and carb was tuned ok enough and it seemed ok after that to a certain degree. (I replaced the carb now, but gotta get it running to tune it!)
13. Pulser Coil Resistance - 848ohm (Spec -> 656-984ohm)
I guess my main questions in summary are:
11. What did I fry?
12. Is the charge coil the motorbikes "alternator"?
... and anything else anyone could kindly point out. I would be greatly appreciative of your time and endeavour to give back as much as I can.
I have worked on cars alot, and have good knowledge there... I'm just learning motorbikes now =(