I have a 97 sport that wont run. I have a friend who works at a local shop looking at it now but we cant find any information for electrical components.
. We have replaced the exciter coil and battery. There is a nice strong spark and fuel, but just still wont run.
What is the peak voltage of the coil?
He was also mentioning something about the reverse rev limiter?

If anyone has a good service manual please let me know. I have a Haynes manual but it does not have much information.

Thanks

 

If you have good spark and fuel, you need to check the compression. These bikes will not run if it is too low. As for the peak voltage, do you mean the exciter coil or secondary ignition coil? The rev limiter can be disabled by disconnecting the black wire coming from the cdi module. Hope this helps.

 

It has a fresh top end, there seems to be plenty of compression, but i don't have a compression tester to test it. I was after the peak voltage of the secondary coil, not the exciter coil. also is there any tests that can be done on the CDI?
The thing wont even attempt to fire even with spark and fuel.

 

I do not know what the peak secondary voltage should be, but I would think it should be at least 15 to 20 kilovolts. There is no test for the cdi I know of, mine was bad and determined that because everything tested ok. If you have good spark your cdi is working. I have to ask, is the piston in correctly?

 

That was one of the first things i checked. The arrow was pointed to the pull start/stator side, which is the way the Haynes manual shows it.

I appreciate your help man, I'm at a loss with this thing. Any other ideas you might have please let me know.

 

Are you checking spark at the plug? Was the cylinder bored with new piston to match? I have the same bike and just went through the top end and ignition system myself.
I have to go help my buddy analyze a fuel injection problem on his van, I be back in about an hour and check your reply.

 

The cylinder has been bored, new piston, new bearings in the bottom end and all new gaskets,the carb is spotless, also a new battery. The case has been TIG welded in one small spot and it is a good weld. I dont know a lot about testing electrical components, thats why I have it at a buddies house, he works on atv's, motorcycles, and boats at a big shop here in town. He is baffled, says it has plenty of spark to run after he changed the exciter coil, not really sure where he is testing it at though.

Whats the chances of a flywheel being bad? I know 1 magnet was knocked off and epoxied back on, but looks as good as new with plenty of magnetism.
I really hate to go throwing money around on $300 parts. But I'm almost convinced its either the flywheel, stator or CDI.

 

Well in my opinion, if you have spark the CDI is ok as well as the other parts you are concerned about. I personally would revisit the basics. Get your buddy to check the compression first. He should have a compression tester. If the magnet on the flywheel is not in the proper position I guess that could cause a timing issue, but I'm stabbing at things. Did the bike run before you had the top end done? Usually in most any engine if you have spark and fuel with a no start,its either compression, plugged exhaust or timing. Hopefully someone else will get involved to help you resolve the issues you are having. I will sleep on it and let you know if I come up with another suggestion. Keep us posted on the progress as I would like to know what the problem was. Good luck Bill

 

I guess I was wrong about the spark. He said he was getting about 50 volts. He is going to test the compression today too just in case. He think it could be the flywheel since it was damaged at one point. Bit then again he said he's only seen 1 flywheel go bad in his years of working on them.

Any chance you could get me a voltage reading from your exciter and secondary ignition coil?

 

Yes, I will get back to you later this afternoon. Have your friend check the resistance on the plug cap on the coil wire,it just screws off.Then check the resistance from the primary coil connector to the end of the plug wire,w/cap off. Note these readings and I will let you know if these are within specs.