Hello All,
I have a 1991 TRX300FW that is suffering from no spark
I got this bike as a basket case in non-running condition.

I have replaced with new parts the following: ignition module, ignition coil, spark plug, pickup coil, stator, and voltage regulator.
Every wire in the ignition system has continuity to where it is supposed to. All grounds are good. I use a fully charged car battery when cranking and checking for spark. I ground the spark plug with a jumper wire to the starter ground.
The ignition module and coil are a set from amazon.
The pickup coil is from caltric.
The stator and voltage regulator came as a set from caltric.
I first replaced the coil, ignition module, and sparkplug. I have also tried every combination of old and new of these three parts.
I next replaced the pickup coil.
I finally replaced the stator and voltage regulator together.
I have not seen a single spark.
I am only left with a couple of options at this point:

1. It is possible that someone was in this engine before me and replaced the stator or fly wheel with incompatible items. When I opened up the case, there was a 12 pole stator, and I replaced it with a 12 pole stator. There is also an 18 pole stator available for this bike, which would be incompatible with a 12 pole flywheel and vice versa. I really don't think that this is the situation though because the case appears to never have been opened. If it was ever opened, it has certainly ran since then.

2. One, or more of the components that I replaced were replaced with failed, brand new components. Although rare, this is certainly a possibility.

I would really like to bench test both my new and old ignition system, but I can find no information on what signals should be coming from the pickup coil and what signals the ignition module should be outputting to the ignition coil. I have an oscilloscope and can read the output of the pickup coil, but I have no idea what to compare it to. Ideally, I would like to be able to hook up the ignition module, coil and sparkplug and generate the appropriate signals to the ignition module, just to verify functionality of that portion of the system.

Does anyone know what the inputs and the output of the pickup coil and ignition module should be?

Is there anything else that I am missing?

Thanks in advance for your help!

-Justin

 

Honda repeatedly altered the wiring and CDI on the 300 model, are you sure you got the right CDI for that year of bike. The wiring plug colour is the only indicator of which CDI you should be fitting. There are at least five different ones, and three use different coloured versions of the same wiring plugs. Did you do all the checks Honda recommend at the wiring plug, earth earthed, positive, live with ignition on and kill switch in the central position, neutral light wire working, this is the bit Honda kept changing, neg in neutral on one model, neg when not in neutral on another, I think one was even pos in neutral, but not sure of that.