IC (igniter) failing? NOT! We have a winner!

[audiogooroo]

Edited 10/20/08
And the winner is....Lomax!

After getting to work the weekend and not having time to look at it, I pulled the ignition switch and guess what I found? Yep, the resistor had separated at one end where it was soldered in place. I completely rewired the bundle to the connector because I didn't like the way it looked, plugged it in and she fired up and purred like she should.
A simple (and free) fix. Thanks to all who offered up their gray matter to help me figure this out. You guys rock!

Original post:
So I fire up the bike this morning to run some errands and then remember that I left my wallet in the house. Shut her down and retrieve wallet. Hit the starter again and she just cranks and won't fire. Pretty clear that it's not getting any fuel, but I just put a new fuel pump in. So I pull the seat and and tank, unplug the fuel pump and grab my multi-meter. Fuel pump checks out fine, showing resistance where it should. Next step, simple confirmation...using wire leads I connect the ground and 12v+ to the red and yellow wire connectors on the pump. It snaps to life and starts pumping gas just as it should. So now I'm thinking wiring problem. Out comes the meter again and while I do show 12v+ at the red, the yellow shows zilch.
Time to look at the wiring schematic in my Clymers. It shows that the yellow runs through a diode and to the IC (igniter). I'm assuming this is to control the amount of flow the fuel pump generates? I check all wiring and connections and everything looks good.
So, all of this to say that it's looking like the problem may be in the IC. A new one is $256 at Mr. Cycles.com. But I don't want to go that route until I know definitively that is the problem.
Is there a way to test the IC before I replace it? Clymers only suggest dropping another one in to see if that's the issue. Don't know about you guys, but of all the redundant parts I may choose to keep on the shelf, that ain't' one of 'em!
Any ideas, oh KawaNOW brain trust?

[cactusjack]

AG,

I am looking at my 2007 Kaw service manual. I don't know what would be different between a '99 and an '07 as far as the IC igniter is concerned. It has a full-page troubleshooting flow chart for it. I don't have the ability to scan a page in a book. My scanner is sheet-fed. but one thing it says is to check the crankshaft sensors. Here it is in Reader's Digest condensed version:

> Inspect ECU and crankshaft sensors

Do above inspections prove that IC igniter in ECU and crankshaft sensors is good?

YES - replace ECU
NO - replace damaged part

> Does engine still operate poorly?

YES - replace crankshaft sensors
NO - replace part which was not replaced above

> Does engine still operate poorly?

YES - trouble may be caused by other ignition system component or engine itself.
NO - End

Not a whole lot to work with there. Sorry.

[lomax]

...Audio
If you are sure its not a fuel problem, then you have probably checked the obvious electrical stuff like fuses and connections. Some have run across the ignition switch as causing probs like this. You may have to take it apart and clean or flush it with some contact cleaner. There is also a resistor in the switch, in one of the wires to the IC igniter, and if blown, she ain't gonna start. Just something else for you to check. Good luck!

[skyhookman]

I looked in my factory manual, it say basically whats listed above, to check crank sensors emergency stop switch, kick stand switch, clutch lever switch, and ignition switch and circuit. It stays completely away from the icu circuit check, must not want use to fool with it.

[ringadingh]

My bike has been doing the same symptom this past week a few times. Ive managed to get it started by turning the key on and off a few times until I can hear the fuel pump whine. I think its a worn ignition switch in my case, I'll replace it over the winter if it lasts that long.

[nomad]

would it not be easy just to check a plug for fire then move on to the fuel? if the plugs are hot then it could be an injector issue. the fuel pump works but the injectors will not let the fuel into the cylinders...just my 2 cents worth. good luck.

[macmac]

Check the yellow wire in OHMS after disconnecting the BATTERY to test the diode.

A diode passes current only one way, so if you get a reading reverse the leads and pray for no reading..

Then re-connect the battery and switch to DCV mode, and power up the fuel pump, and test the yellow wire for voltage to the the IC.

Probably the IC gets a reduced voltage, so be sure to check in lower dc volts settings with the meter, maybe down to 1/2 volt.

Probably the fuel pump is used to switch the IC, but the fuel pump will not deliver more or less fuel for this reason.

I was away, and so lost the details, of if you found what fuel pressure was. I have my doubts if is anything over 7 psi.

I have never seen a carb set up on a Nomad, so I don't know if there is a fuel return from the carb to the gas tank. If there is, it would be the needle and seat valve could be over pressured on purpose, and so fuel could flow to the carb and back to the tank.

There probably is no return line as a wild guess though.

So with out ever having seen this set up, my best guess is the yellow wire is turned on at the pump current feed, and a signal for IC demand takes place.

It would be good if perhaps you have a helper to crank the engine to start so you can check dc volts at the coils. If there is none, work back to the IC, seeking any voltage even 1/2 volt.

[audiogooroo]

Thanks everyone!

[blowndodge]

Beers on audio this coming summer!!!

Nothing like a free fix!! how cool is that!?

[audiogooroo]

Originally Posted by Blowndodge "Darksider"

Nothing like a free fix!! how cool is that!?

Way cool! It's exactly to the penny what I had budgeted for bike repairs this month. ;)

[dkdixie]

Great news......glad you found and fixed the problem!!

[lomax]

......good news Audio! Easy fix, and cheap too! Gotta like that! :)

[cactusjack]

This is one of the things that makes KawaNOW so cool - a vast pool of technical advisors ready to offer assistance when needed. AG, I'm glad you got your problem fixed for cheap!