I have followed many of the troubleshooting on here for the 5 pin cdi boxes . I have replaced stator because I only get .02 ac volts out of the blue wire , replaced stator and get the same results. What am I doing wrong? Thank you

 

Makers like Honda and Suzuki recommend using a peak voltage tester to get accurate results when testing ignition circuits. What ohms are you getting from the old stator pulse coil and the new one? Were you testing at the stator plug or at the CDI? If at the CDI try testing at the stator plug and, if different, you have a fault in the wire between stator plug and CDI.

 

I have ohmed out the blue wire for the pickup on new and old stator , both ohm out at 130 ohms . There is no way to adjust gap on pickup to flywheel. Even if I check blue wire right out of stator before cdi I get .02 ac volts which I assume is not enough and why it's not getting spark . The groud wire checks out the red a/c power wire checks out , cannot figure why no spark . Thanks for any help!!

 

Either that 0.02v reading is wrong or you have two dud pulse coils. I would be getting a new CDI, for the price of them it is worth trying that. I do prefer testing to throwing parts at a problem, but testing doesn't always work. The Honda 90 manual, which is the only one I have for that type of Honda/clone engines, gives 50 to 200 ohms for the pulse coil, as being right.

 

Just installed a new cdi , still same results no spark . I am getting 40 volts a/c out the red and black at cdi plug while cranking. .005 a/c volts is the best I can get out of the blue wire while cranking. If I ohm out blue to green ground it is 130 ohms. If I ohm black to green I get 130 ohms also . If even if I check blue wire right when I comes out of case it is the same reading . This is the second stator because I thought first one was bad after not getting enough of of blue wire but know I am getting the same results and help would be great . Thanks

 

Have you tried the voltage reading between wires to ignition coil when cranking? That should be quite high, often over 100v so care is needed. If you are sure both pulse coils are faulty, all you can do is get another, but especially with a new coil, for it to ohm out right and be wrong, is unusual.

 

I will replace the coil tomorrow, the stator. Cdi , and coil will be new . Those are the only items needed to make spark . I just don't understand why the pickup only puts out .025 at most , same reading I was getting out of original stator . The engine is less than 2 years old

 

I have replaced stator , cdi , an noe coil , still no damn spark . I have dumped more money in this gocart than I should and probably none of its bad . I cannot figure out why this thing will not start , any help would be much appreciated. Thanks alot !!

 

Right. Go back to the wires at the CDI plug. Check the earth(s) are earthed, that the kill wire is earthed with ignition switch one way and not earthed with it the other, probably earthed when switched off on a Coolster, double check resistances on the stator coils at the CDI. Check the voltage from CDI to ignition coil when cranking on the starter, should be a high voltage. If you are getting a high voltage there, either ignition coil, HT lead, or spark plug is the culprit.

 

The kill switch wire has been removed from cdi connector so that is no an issue. Good ground or earth from green wire on cdi connector to frame ground. Get 50 volts a/c voltage put of red and black wires in stator, very low .025 a/cvolts coming out of pick up coil , same results with 2 stators