No spark

[Hooli]

Low voltage could be a dodgy earth, which would also explain the poor/intermittent spark.

[Rod G]

Hi Lawrie, 
I'm not able to help you pin point the problem, but I applaud your rational approach to isolate each item in the iggy loop, coils, ECU etc.  My experience with iggies over a long life is that problems mostly occur in the iggy switch, ECU or EI units, and dry joint cable connectors.
I'm certain I'm not telling you anything new here, but this is where I'd be expending all my energy.  Just one dry joint in the harness and you get high resistance and with it, reduced voltage.  Good luck in your search

[Rod G]

Low voltage could be a dodgy earth, which would also explain the poor/intermittent spark.

Yes good advice this.  I failed to mention it.

[Andre]

The manual specifies a 'peak-voltage' setting, so I'm assuming a specialist meter??
My meter is a high-end device, but is still a basic unit & when I did the tests, I was getting readings but not sure if they relate to the manual's  specs.

I think the Fluke 87 meter (Very expensive) has peak-voltage function. There are also peak-voltage adapters for "normal" multimeters. These are still expensive. Here is a link on how to build one yourself for pennies.

https://thumpertalk.com/forums/topic/1034259-build-your-own-peak-voltage-adapter/

Certainly good to have this adapter in the tool box.

[lawrie]

Well after several more hours disconnecting, checking, cleaning & re-connecting, I'm no further forward, all B/W earth wires check out ok & all are in good condition, as for the 'peak voltage adapter' above, i'm going to make one & see how we get on!!
Getting a bit baffled now.
I'm even considering taking bits off the good bike, swapping them over, one at a time to gradually confirm & eliminate components, bit of a ball-ache, but at least I have the capability to do so!!

[Andre]

Have you taken the ignition switch apart and cleaned its contacts yet?

[gsxbarmy]

I'd also try swapping batteries - even good ones can go iffy from time to time, has caught me out a couple of times Lawrie (and a simple thing to try)

[turner]

Hello, may be coming in late on this but, last year i had a problem with rough running tick over miss fire. whilest trying variouse thing s my mate was at the front off the bike when i reved it up he said your light just dimmed !! at this i checked voltage on tick over.ok on reving it dropped below 11 . disconnected battery, reached under bike disconnected voltage regulator/rectifier. cleaned with electrical cleaner re assembled and everything back to normal readings, and running. poss not getting right voltage to main components at said requirements.

[grog]

as above. it has spark but weak and low voltage the clue. why? battery is the start. if not it, need to find weak link. battery has also tricked me on cars, hondas, v8 toyota, demand perfect volts or just crank and not start. if you solve your prob, can you solve my headlight only working sometimes. i cant. have checked all i know.

[lawrie]

A few more hours today, it has a brand-new gel battery that starts the other 1400 instantly,  brand-new plugs.
Since its ALL 4 not working, I'm doubting the coils or anything common to them all.
Checked the side-stand switch, took out the crank-position sensor, & its within spec.
Re-assembled, turned it over, & did see weak sparks for a few cranks, & the plugs were fuel-wet, so i'm still inclined to go for electrics rather than fuel.
ALL earths check out good, but I seem to be losing 1/2 volt  (11.6v) everywhere there should be 12-13v.
However, the starter is getting the full whack & spins the motor fast.
I have yet to implement the ign-switch strip, I just about ready to get the bikes side by side & start swapping back & forth until  I get a result!!

[Rod G]

I have yet to implement the ign-switch strip, I just about ready to get the bikes side by side & start swapping back & forth until  I get a result!!

I feel your pain Bro!

[Andre]

The good part of all this PIA is that you will have a thoroughly checked electrical system. Although I don't have any problems, I only have a few more connectors and wires to check and maintain.

[lawrie]

UN-BLOODY-BELIEVABLE!!!!
Well, I bought all the components & made up a peak-voltage adapter to fit my multi-meter,  then went through all the various tests on the different sensors etc.
ALL checked out OK!!
Now I'm starting to question my 'limited' abilities, & once again whilst laying the plugs against the frame, I noticed that the although the plugs weren't actually sparking, there WAS a big fat spark from the plug thread to the frame.....EH?
Exactly the same for all 4 plugs, so I metered them & they seemed to be fine according to the meter, but no spark!
Luckily I still had 4 old plugs, tested them & they were the same, last ditch effort I fitted them, BAM! Away she went as soon as I touched the button  WTF  is going on???
How the f*** can 4 almost new plugs check out good but not spark, & the real worry is that a month or so ago, I fired her up & she ran no probs, so I wonder if there is still an underlying electrical problem somewhere.
There is another 'hiccup' ( there just had to be ) although it instantly fired up, she went straight up to about 4  thousand rpm, no throttle, so i'm now wondering if somehow I 'knocked a sensor out of plonk' whilst testing, so more messin about, at least its running
( for now ) 
Watch this space 

[lawrie]

SORTED!
It starts & runs like the day it came out of the factory, tweaked this, tweaked that, a but of pushing & shoving & all is well again, just cant believe I had 4 dud plugs, tried them in the other 1400, no go!!
Don't know what the tickover SHOULD be, but its nice at 1000 rpm, running the old plugs for now, but will get 4 new-uns next week, I wonder if THEY will work!!

[gsxbarmy]

That is really odd, 1 dud plug I can understand - but 4? Very odd!!

Well done on persevering Lawrie!!!