OK so this is my issue.

the bike was a 110cc forward reverse Taotao.
i pulled the engine out a few years ago and sold it as my daughters were not old enough to ride yet.

it sat in a dry garage for the past 2 years no rain or corrosion or nothing.

i just bought a brand new engine. that i installed a 125cc because there is no more 110cc forward reverse apparently.

there is power to everything except the forward lights.
Fuse is good and has been changed.
cranks over no problem at all.
just no spark.

so i have 3 cdi, all brand new that i know work they work in my other atv another taotao.

i changed the ignition coil , cdi , brand new spark plug, brand new ignition key switch because that was not working properly.
i unplugged the tether cord from the wiring harness to make sure its bypassing. i push both the foot brake and hand brake when turning over sill no spark.

i ordered a new start kill switch from ebay but wont be here for a month.. but does anyone have any idea of what it could be. my entire wiring harness is good no brakes or corrosion anywhere.

im assuming that the staor magneto is good as it was a brand new in the box sealed engine.

any advice would be greatly appreciated.
im assuming its something stupid somewhere and simple but im actually stumped as to why i cannot get spark.. ive spent 400$ on this atv as of right now.. another 300 bucks and i could of gotten a brand new one..


Thank You in advance for any advice

 

pull the wire out of the cdi that controls all the safety features. I think its black with white trace. If it starts then you have a switch issue some ware. From what iv seen is usually the brake switch goes bad

 

ok also I don't know if the are supposed to but.. headlights aren't coming on. at all ..
brake light comes on .


and in reference to your mentioned advice. if I pull that wire out it will bypass all safety and cut offs ?


I know there is the tether
and brake switch
and the switch on and off where the start button is with headlights etc.


thanks

 

The center pin for the CDI box is for the safety features. If you unplug it, essentially you are bypassing the tether, alarm box, and kill switch. If you get spark when this wire is unplugged from the CDI, you know that the issue lies in one of the safety systems.

Secondly, the headlights are stator-driven and will only illuminate when the machine is running.

 

ok so i cut the wire. middle wire for the safety switches etc.
everything i have used on this bike works on the other bike i have outside.
so im stumped..

its apparently not any of the switches..
i just dont get it unless its the stator ?
it shouldn t be its a brand new engine..

how would i test if thats working ?

im freaking fed up lol. been working on this everyday for 2 weeks...

i should of just bought a new bike..
ive ordered all new ignition parts again just in case but as i said everything works on my other atv..

 

After cutting that wire, are you getting spark at the plug? You can test this by removing the spark plug, putting it in it's boot and holding the threads to a non-painted piece of metal on the frame.

 

yes i did that no spark still ..
im above average with mechanical skills
this is why im saying im freaking stumped

 

Since you have exchanged the other parts with your second machine, I'm inclined to say your stator is bad or the pickup coil isn't spaced correctly.

 

thats what i was thinking...
that or some silly flaw in wiring somewhere but
i took old engine out everything ran 100%
put this one in brand new all the right plugs etc.
all new parts lol.. still nothing i ordered complete wiring harness too waiting for that ugh.

electrical is the one thing that messes with my head.. and im ready to smack my head into the wall !

 

ok so an update..
I checked the stator. and pick up


stator is reading 560.. supposed to be 380 ish give or take 10%


so would that be enough for no spark?


also I took a stator of the spare bike which is a 110cc loncin motor forward only and the engine in question is a 125cc loncin forward reverse
they look total different but bolt up
same wires
readings are where they should be.
134 ish and 380 ish
but still no spark.


but being as they are from 2 dif bikes and are in fact different does that make a difference


thanks