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Old 01-03-2016
lyrrad66 lyrrad66 is offline
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Join Date: Mar 2016
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Intermittent Spark

Hi There, came here as a last resort hoping that someone out there may have had something similar or at least be able to point me in the right direction. I bought an old suzuki TSR200 1992 model as a project. I have rebuilt from the ground up. Looks old but internals are good. Prior to this I had never had it running. I have an issue of intermittent spark, well heres the lowdown. I have a new coil so rule that out. I can bring the thing to life by "exciting the circuits" By this I mean that I can unplug and replug the headlight with the ignition on and sometimes this brings it to life. Sometimes it takes me to switch high/low beam and it will come to life and run ok. Last time I rode it after about 30 mins it began to miss and die. After 5 mins it started again but same thing happened which tends to tell me its a heat thing. Only trouble with that is when I can start it I can switch straight off and it will start again - even dead cold. Leave for a few hours and no spark.

I can run in the garage and then leave overnight and wham, no spark. All resistance checks ok (even when no spark). Wiring loom has been inspected thoroughly and all earths good. Im thinking either CDI or pickup coil. Please help!!
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Old 02-03-2016
nocams nocams is offline
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Join Date: Apr 2012
Location: Blue mountains
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I had a similar problem with my rd350lc,it would only start when left out in the sun or a hot day in the shed. Cdi was rooted.
You've nearly got it sorted by the sounds of it.
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Old 02-03-2016
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Battered Sav Battered Sav is offline
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Dodgy kill switches and plug caps come up pretty often.
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Old 02-03-2016
lyrrad66 lyrrad66 is offline
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Join Date: Mar 2016
Posts: 2
Thank you for taking some time. New coil and plug cap and all kill switches bypassed. Im thinking CDI but is a very expensive mistake and finding one to borrow is almost impossible. A catch 22 scenario.

To rule out pickup coil can you check with a test light for pulse? I could do that when no spark scenario. How do I do this?
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