Tao Tao 200CC No Fire-Need Wiring Diagram
#11
Join Date: Dec 2008
Location: Tracy, California, USA
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Hi Tim,
My comments embedded in blue...
The AC Ignition Power wire goes to the stator through another set of connections near where the stator wires emerge from the engine through the side cover. Find the AC Ignition Power wire at this set of connectors. It is probably blk/red, but see what the color is at the CDI pin. It will be the same as it is at the CDI pin.
Disconnect the AC Ignition Power wire and measure into the stator to engine ground.
1) Is the resistance still the same (280 ohms)?
2) Is the AC voltage while cranking still the same (61 mV AC)?
If so then it looks like your stator is bad.
My comments embedded in blue...
LynnEdwards,
I finally had some time to troubleshoot the CDI with your directions and a decent meter. The results are:
1. Kill Switch Pin to ground = infinite ohms [OK]
2. AC ignition Power pin to ground = 280 ohms [Sounds low from my experience. Maybe some of the turns are shorted internally...]
3. Ignition Trigger Pulse to ground = 155 ohms [OK]
4. AC Ignition Power pin to ground while cranking = 61mVAC [This is wrong. This coupled with "2." above suggest that the Ignition Power winding in the stator is bad].
5. Ignition trigger pulse pin to ground while cranking = 180mVAC [OK]
6. CDI plugged in. Ignition coil pin to ground while cranking = 0VAC [Not OK, but understandable since you have no AC Ignition Power]
What's your opinion?
Thanks,
Tim-
I finally had some time to troubleshoot the CDI with your directions and a decent meter. The results are:
1. Kill Switch Pin to ground = infinite ohms [OK]
2. AC ignition Power pin to ground = 280 ohms [Sounds low from my experience. Maybe some of the turns are shorted internally...]
3. Ignition Trigger Pulse to ground = 155 ohms [OK]
4. AC Ignition Power pin to ground while cranking = 61mVAC [This is wrong. This coupled with "2." above suggest that the Ignition Power winding in the stator is bad].
5. Ignition trigger pulse pin to ground while cranking = 180mVAC [OK]
6. CDI plugged in. Ignition coil pin to ground while cranking = 0VAC [Not OK, but understandable since you have no AC Ignition Power]
What's your opinion?
Thanks,
Tim-
Disconnect the AC Ignition Power wire and measure into the stator to engine ground.
1) Is the resistance still the same (280 ohms)?
2) Is the AC voltage while cranking still the same (61 mV AC)?
If so then it looks like your stator is bad.
#13
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61 volts is OK for ignition power. So we've got trigger signal, power. and ground to the CDI, yet there is no output to the coil. Now the finger points at the CDI, which I believe you have on order. It seems the best course now is to wait for the new CDI. If that doesn't work then we can regroup and dig in deeper.
#14
Finally
Thanks for all the help LynnEdwards. After eroniously sending me a voltage regulator, the parts place finally delivered our CDI yesterday and success has been achieved. It runs. It is obvious that it needs adjustments because it has to run on about 3/4 choke. Once it is warm it idles well but getting it warm is a bear.
The CDI was in fact faulty but it seems as though the kill switch does not reset very consistently. It is the type that has to be pushed in to reset but I usually have to do it 3 or 4 times to get it to start. Is there any harm in turning off the key instead of using the kill switch? I may try to figure out the switch contact arrangement and use some sort of more durable switch. Unfortunately, the kill switch, throttle and starter switch are all one assembly on this quad. I considered mounting a snap switch somewhere else for killing the engine. Any ideas?
The CDI was in fact faulty but it seems as though the kill switch does not reset very consistently. It is the type that has to be pushed in to reset but I usually have to do it 3 or 4 times to get it to start. Is there any harm in turning off the key instead of using the kill switch? I may try to figure out the switch contact arrangement and use some sort of more durable switch. Unfortunately, the kill switch, throttle and starter switch are all one assembly on this quad. I considered mounting a snap switch somewhere else for killing the engine. Any ideas?
#15
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....After eroniously sending me a voltage regulator, the parts place finally delivered our CDI yesterday and success has been achieved. It runs. It is obvious that it needs adjustments because it has to run on about 3/4 choke. Once it is warm it idles well but getting it warm is a bear.
... Is there any harm in turning off the key instead of using the kill switch? I may try to figure out the switch contact arrangement and use some sort of more durable switch. Unfortunately, the kill switch, throttle and starter switch are all one assembly on this quad. I considered mounting a snap switch somewhere else for killing the engine. Any ideas?
There is no difference in operation of the kill switch part of the ignition switch or the handlebar kill switch. Both work the same way - as does any remote tether kill switch or remote control module kill switch if your quad has these.
If you add your own kill switch keep in mind that the switch has high voltage on it when the engine is turning and the kill switch is in the "run" position. So don't install a system where fingers get into the wiring when attempting to kill the engine [for example - who needs a kill switch? I'll just twist these two wires together whenever I want to stop the engine...]
#16
Thanks LynnEdwards!
I want to thank LynnEdwards for the work he has done with finding the electrical values for trouble shooting no spark issues.
My TAO TAO 250D quit a couple of weeks back and I an in the process of trying to get it running again. I replaced the CDI and the ignition coil this morning but still got a weak/no spark. When I tested the system following LE's guide I see that I am getting less than 5 volts AC (mine is a AC system) from the ignition power. Which is less than a few days ago when it read near 30 volts AC. I am assuming that means my stator main is bad. I have a new 8 coil stator ordered just now from China.
Incidentally for any of those needing to replace your magneto stator. The easiest way is to pull the plastic footrest assembly from the left side of the ATV. There are 8 screws and bolts to do this. Than remove the gear shift lever, and the cover. You need to remove the cover to the starter (3bolts) and the gear assembly to access one bolt that holds the larger magneto cover, as well as the outside bolts around the covers face. You do not need to remove the small chrome face cover (4 bolts) that is inset into the larger cover.
The cover might be a bit sticky and need to be lightly rocked away from the starter motor and a flat screwdriver inserted between cover and engine to equalize the pull.
I hope the new stator fixes my problem. It will be a couple of weeks before I get it I imagine.
My TAO TAO 250D quit a couple of weeks back and I an in the process of trying to get it running again. I replaced the CDI and the ignition coil this morning but still got a weak/no spark. When I tested the system following LE's guide I see that I am getting less than 5 volts AC (mine is a AC system) from the ignition power. Which is less than a few days ago when it read near 30 volts AC. I am assuming that means my stator main is bad. I have a new 8 coil stator ordered just now from China.
Incidentally for any of those needing to replace your magneto stator. The easiest way is to pull the plastic footrest assembly from the left side of the ATV. There are 8 screws and bolts to do this. Than remove the gear shift lever, and the cover. You need to remove the cover to the starter (3bolts) and the gear assembly to access one bolt that holds the larger magneto cover, as well as the outside bolts around the covers face. You do not need to remove the small chrome face cover (4 bolts) that is inset into the larger cover.
The cover might be a bit sticky and need to be lightly rocked away from the starter motor and a flat screwdriver inserted between cover and engine to equalize the pull.
I hope the new stator fixes my problem. It will be a couple of weeks before I get it I imagine.
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