Hi all I bought a 150cc falcon it's in bad shape the guy who sold me it
said it was his sons it was running he said but you have to start it
with a power drill on to the flywheel nut starter dont work anyway
got it in to the shed and started to strip it down here is what a found

1 all the left cluster wires had been cut so a small repair was needed now fixed

2 starter clutch 6 bolts sheared now replaced and working ok

3 staitor wires cut and connection blocked now rewired

4 missing coil now replaced

5 missing cdi now replaced

6 no battery new one installed

so a had the falcon turning over but it was real slow and no spark
and also the staitor was well hot to touch I thought there must be a short at first thought it was the staitor but checked the starter motor first
i opened up the starter motor and it looked like the windings were touching the bottom of the casing so i put a plastic washer in to check and refitted the starter the starter turns it over fast now the staitor is now cool but still no spark any ideas.

thanks scotty

 

Yikes, what a basket case.

The stator being hot makes me thing the voltage regulator is shorted allowing battery current to flow backwards through the stator's battery charge winding. If your battery goes dead quickly if you leave the ignition on with all lights off (including the brake light) then look at the regulator.

So do you know if this engine will start up? Ever seen it running? With all the other problems I'm wondering why you bought it.

"He said but you have to start it with a power drill on to the flywheel nut" is a big red flag in my book (and I like challenges).

First thing I would do is measure compression, then figure out why no spark.

Do you know if your quad is wired for a AC or DC powered CDI? Which CDI did you install?

 

I bought the bike as a project to do up for myself, no I never seen the bike running, it never ran, I got it for £80, which is roughly $45, so it was a deal, the reason he was starting it with a drill was the one way clutch was shot, he obvisiously did not know this; the compression is fine and now I have got it turning over ok now, I replaced the cdi with a factory cdi for a 150, so it is the standard one, I will replace the voltage rectifior and if still no joy I will replace the stator.

cheers for all the help.

scotty