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On my last ride of the season last year, a wire was loose and shorted to the frame, causing some smoke. Result is the bike will crank but not fire. The fuel pump no longer primes when switched on. I replaced the main relay because it did not click when switched on. This new relay installed does work, you can feel and hear it click. Does this mean the CDI box is working or no? Also the fuel pump does still work. What other things should I check?

Thanks for the help.

Before DonTZ125 reads this I want to tell you that it is a TCI not a CDI as many of us commonly refer to the ignition box. Chances are good that you need another TCI since I believe it not only controls spark but turns on the fuel pump. I remember reading this somewhere but I can't verify it.

thanks for correcting me! thats what i thought also. seeing as the "TCI" isnt cheap i wanted to ask.

hi,
Ok battery fully charged, if you hit the start button what do you hear? Nothing, then the fuel pump is not getting current so stat checking every fuse not just the ones in the main fuse box.

Does the voltage regulator small burned at all? what type is it tin can or cast & finned case VR>

I would be asking what wire was it that grounded on the frame would make me think of what area I would follow on the wiring diagram.

rotortech wrote:Before DonTZ125 reads this I want to tell you that it is a TCI not a CDI as many of us commonly refer to the ignition box.

(insert *thpthpthpthpt* smiley)

rotortech wrote:Chances are good that you need another TCI since I believe it not only controls spark but turns on the fuel pump. I remember reading this somewhere but I can't verify it.

This is a true fact - the TCI does ground the pump to turn it on.

Don - thanks. I am glad we are working together on this one.

could be the main fuse, could be the pump itself, could be the TCi. i once shorted a wire to the frame and it fried the main fuse. the fuel pump gave me a hit in the ba11s once, but it wasn't because i shorted a wire, but because it was just the end of her life. the last time i shorted a wire to the frame it took the TCI out so i bought another one (it was beyond repair, as the main chip, or how it's called got fried and the bike was making implosions in the exhaust because the TCI was not sending the ignition signal on time)

Do the obvious first. Disconnect the fuel pump connect the power supply to the fuel pump wire to the multimeter and ground the other multimeter lead on the battery. Turn the ignition on, if you get 12v for 5secs the relay etc is working and the pump is probably fubared (the pump can be checked by applying 12v directly to it). If you don't get 12v then it is a relay, a fuse or the TCI.