[tahoemike00]

I suppose to some extent the year, make and model (05 crf250r) is irrelevant to a certain point. More of a general process question I guess.

I want to test for spark by putting a plug in the cap, place electrode on part of the frame or bolt and kick to see if there is spark present.

I ended up getting *shocked BIG TIME* when grabbing the plug cap/coil after kicking and testing for spark.

How do I run these spark test without getting 40kv pumped though my body after kicking to check for spark? I've only seen one other post where they said this has happened.

Is there a way to discharge the stored voltage? I have to assume the voltage is in the actual plug cap/coil (COP) and not the ICM.

[JimDirt]

The way to avoid it is to NOT hold on to it , lol

They make tools specifically for this procedure , but you can make a basic one with a clamp like on a battery charger and a length of wire , OR just a length of wire , you simply strip enough of the cover off the wire to expose enough bare wire to wrap around the plugs metal area , like the plug nut area or threads , and ground the clamp to a suitable location (or ground the other end of the wire directly) , as long as the metal body of the plug is grounded in some way , the plug , if functioning properly will spark

You should not be getting shocked at all AFTER you have completed the kicking procedure , there should not be any "charge" in the wire , if there is i would be looking for a direct short or a bad ground

Hope that answered your question

[tahoemike00]

Actually what happened was that I did a valve shim job, reassembled then went to start it. Nothing, after several kicks and push starts not even a pop. Pulled the cap and plug to do the spark test and that is when I got bit. Happened again after I put in a out of the box new plug.

But the crazy thing is that I did see spark when I had the plug out of the cylinder and touching bolt or frame. Put the plug back in and tried to start again but nothing. Another zap when trying to remove the plug cap.

At that point I read about timing marks on BOTH sides of the cases via the inspection ports. After I figured out how to get TDC at compression stroke, I realized that I had the cam improperly aligned. So I realigned and reassembled.

But unfortunately it's still not starting. But now I am afraid to touch the cap again to check for more spark -- at this point I am wondering if I fried the ICM/CDI box if at one point I had not grounded the spark plug properly during the kick/spark test. Read somewhere that can happen.

[JimDirt]

Yea it is possible to fry the CDI from not grounding the plug , i am also concerned about the timing issue , have you rechecked to make sure the cam marks are level across the head when the timing marks on the left and right side are aligned up ?? , but getting zapped with nothing running is also a issue , something is wrong there , do you have a Service Manual ??

If so you need to test the ignition system just to rule out everything

But still you should not be getting zapped by a non running engine i cant think of anything that should hold a charge , you are not getting zapped when touching the engine or anything else are you ??

[tahoemike00]

I have quadruple checked my alignment/timing. I even watched a couple youtube vids and I am 99.99999% sure I have it set right.

Funny thing is that I have had the cam out at least 3 times in the last 2 or so years, replaced a fried cam when we first bought the bike and then a re-shim. Never even knew about the -other- timing mark, and it started up just fine after each time the cam was out. Dumb luck I guess.

So i am not sure at this point if I have an intermittent spark issue, (possibly because my kid was yanking the plug cover/cop off not-so-gently and possibly damaged it?)and/or if I zapped the CDI box with an incorrect spark check method. There is a also a variable; I was putting in a new (out of the box)oem spark plug and I dropped it on the concrete floor before installing it. Thought maybe I damaged the plug, especially since the first spark test I did was test the old plug that was just removed, and I verified spark on the one!

So when I went to pull the new plug out to put the old (spark tested) plug back in, that is when the cop zapped me. Si I used pieces of wood and insulated rubber covered plier handles to remove the plug cap and put the old plug in, thinking it for sure would start.

Nope. Kicks, push starts, starting fluid, nothing, not even a fart or pop.
My son tried to remove the plug cover/cop and gets zapped to. The spark jumped from the cap to his finger tip, he hadn't even touched it yet.

This is just all crazy.

So I am going to use the process of elimination. I ordered a new plug cap/cop, and new ICM/CDI box. I will try those. Plug cap first, then the ICM box. If neither of those work I have my eye on a stator, flywheel and pick up assembly on ebay.

While I am waiting for parts, I am pulling the carb today to look for clogged jets etc.

[JimDirt]

Yea this kind of sucks because it is not something normal , but , in your quest , i would also recommend looking carefully at every wire and connection and plug in , on the bike and make sure nothing looks out of the ordinary , as i cant think of anything that would release a static charge just sitting there while the bike is off , so i would be looking for a short somewhere

I would also throw away the plug (kind of a spendy mistake dropping it , as the plugs are not cheap)

I have seen systems have intermittent spark , i have seen no spark under load , i have not seen a static spark when nothing is on or running

Are you positive you are not standing on nylon carpet while rubbing your hair with a balloon while pulling the plug boot ??

[tahoemike00]

Oh great, NOW you tell me not to stand on nylon carpet while rubbing my hair with a balloon while pulling the plug boot.

I've been bit by my '05 CRF450R as well, I was having problems with the flywheel and stator. (I had bolted up a Trail Tech flywheel with what was an incorrect type for the OEM flywheel) Anyways, another folly of kicking and push starting and no pops, sputters or fire at all. Someone suggested the coil was bad so I ordered another. Went to remove the existing coil, touched the socket and extension to the mounting bolt and Ka-ZAP!!!! :crazy: I don't like static electricity shocks let alone 20kv or 40kv or whatever juice the CDI and coil pump out on these systems.

Anyways, Back to the 250 - I ordered a new oem plug cap/coil (I'll call it a cop) Figured I'd start there as I was suspicious when my son was trying to yank the cop off by the wire and I noticed that it looked like the wire had pulled out from the rubber housing a little. Hence why I was trying to do spark tests to see if the cop was fubar. I didn't want to fiddle with it anymore which is why I ordered the new one. So while waiting for the new plug cap/coil to arrive I pulled the carb. Discovered crud in the main and a plugged pilot.jet. Cleaned those out and a couple of other jets and orifices that I could find. Got the carb reassembled and installed just as my son walked in with the days mail: NEW PLUG/COIL cop!

I went to install the new cop, put on my bomb squad suit and approached the old cop like it was C4. Used a pair of wood dowels like chopsticks to remove the existing cop.

Then PLOP the spark plug wire fell away from the cop. Only then did I realize that the plug wire and cop where separate and used a connector junction to mate the plug wire to the cop. Duh, felt like a dummy. So I guess when my son yanked on it earlier the connector plug became slightly disconnected, maybe the reason for the intermittent spark issue and maybe why it was biting me. Good a guess as any.

So I had the new cop, figured might as well plug that one in (with dielectric grease applied to the terminal lugs of course)

Slapped the tank on, added a 1/4 tank of go juice, turned on the gas, pulled the choke, twisted the throttle for 3 squirts, then told my son to just cycle the kick starter through a few times to fill up the carb and to suck some gas into the system. Well I'll be a sumbitch, it fired up first kick! He wasn't even trying to start it!! Told him to hit the kill button and try it again. Bang, first kick again. Repeated 5 more times out of sheer giddiness. Did a few victory wheelies down the street. The neighbors love us.

I learned a lot of lessons for sure. I've been wrenching on bike for years (since the 70's) but all 2 strokes. These CRF's have upped my learning curve game.

BTW, thanks for throwing your hat in the ring with suggestions. More responses that I received in -other- forums.

[JimDirt]

No problem glad to help .....well not help , but contribute to your confusion anyway ....glad you got it sorted out , happy riding ! , and stay off the carpet !