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03 fc550 no spark

Joined Feb 2022
2 Posts | 0+
Va
Having some spark issues. the only electrical items on the bike are the ICU10 unit, the stator and the HI/LOW switch. previous owner took it all apart but i cant seem to find a diagram for what each icu wire is for or how i should hook this all up. taff stator was installed and tested to be solid. has red green and black coming off with 3 extra light green wires that were taped off. send help. or someone in the US who can chase electrical gremlins.

motor serial number is 5532003

CDI number - ICU10-855191-13-50285-10
 
there are two versions of the ICU10 "Ignition Module" (I.M).

there is the 5-wire version for the FE and FC models that don't have leccy boot
there's the 7-wire version that DOES have the leccy boot so for the FEe.

FE or FC
red to red bullet connectors
green to green ditto
black to black ditto
orange to orange = kill wire
black to black - the only spade connector

FEe
red to red bullet connectors
green to green ditto
black to black ditto
orange to orange = kill wire
black to black - the only spade connector
also;
grey bullet to grey
white to a white or also may be a blue/white

The yellow wires from the stator
on the FEe
one yellow goes to the rectifier, a small finned box bolted under the frame down below the I.M. The other yellow joins into a red wire that splits into a pair of reds nearby. these two reds can be re and red or red and red/white.
on the FE
one yellow wire goes to earth
the other yellow goes to the rectifier.

to check for spark
only have the ;
red to red, black to black and green to green connected. discomnnect the other 2/4 wires and tape up the orange coming out of the I.M.
remove the spark plug
stand bike on a solid flat platform with the wheels off the ground
wear MX boots
kick aggresively and as fast as you can. don't jump in the air for power (too slow)
don't paddle the kickstart arm (not enough power)
crouch with your head down and your knee in your chest, brace yourself and just fir your leg straight out. the only thing you try to move is your leg straight.

remove the plug cap and have the HT cable end near the head stud/nut
preferably have someone hold the HT lead 10mm from this and YOU kickstart the bike.
better stll, buy a tool that if held near an HT cable 'flashes' with each spark...a brilliant tool.

by having only three wires connected you are keeping to a minimum the 'whats, ifs and buts'.

Taffy
 
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Off my stator I only have red green black then 3 lime green wires. Orange off the box is cut very short. I attempted with just the 3 and got no spark at all. Would this mean the ICU box is bad?
 
yes it would.....well HT lead or plug cap still? also, there's a self tapper down the bottom of the hole that your HT lead is screwed into. Don't yank it....unscrew it. if it doesn't unscrew it'll be because thje self-tapper has become loose. That can be repaired. The I.M. can be repaired anyway.

Cheers

Taffy
 

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