Some quick specs.

==============================
Ign Timing

10deg BTDC @1800 RPM
30deg BTDC @ 3800 RPM

Plug NGK CR8E
Plug Gap .028-.032
Plug Cap 8000-12000 OHMS

Ign Coil Res
Pri .1-1 OHM
Sec 5200-7800 OHMS
(plug cap removed)

Magneto Coil Res
Trig 150-300 OHMS
(green to blue)
Src/Charge .05-1 OHM
(yellow to white)
Charging .1-1 OHM
(black to black)
Output 340W @ 5000 RPM
==============================


Make sure your meter has good batteries and is accurate. If it jumps around get another meter.


Magneto

Voltage (charging coils - output)

Meter to DC
Start bike
Red test lead to pos bat terminal
Black test lead to neg bat terminal
Guess 5000RPM
Meter must read 14~15.5 DC V

If not...

Voltage (Charging coils - no load)

The connector is the black and white one on the right hand side of the engine jsut above the brake cable adjuster.

NOTE: Test the connector coming from the engine, not going back in the harness.

Meter to AC
Start bike
Guess 5000RPM
Test between the 3 connectors for a total of 3 tests
All three tests must produce 60 DC V

(if both of theses fail replace/repair stator)

Resistance (trigger coil)

Disconnect Bat for any resistance testing
Meter to OHMS
Red test lead to green wire
Black test lead to blue wire
Meter must show 150-300 OHMS

Resistance (source/charge coil)

Meter to OHMS
Red test lead to yellow wire
Black test lead to white wire
Meter must show .05~1 OHM

(if both of theses fail replace/repair stator)

Regulator/Recitifier

Disconnect Bat
Meter to OHMS
Test all combos in the chart

Heres the Pic Click,


Hope this helps.

 

Had to get caught up this am, I don't work weekends.

Voodoo does a nich job of explaining doesn't he Swampy. Pics and all. Hope ya find the problem and for sure keep us posted!! I don't have the miles you have so ya never know, I mite be dealing with the same thing later.

 

Hate to see someone down and out, and if we can avoid the dealer price per hour... Whatever you cant find ill take pics of on my machine for reference. The 500 is the same machine, couple more CCs

 

well I talked to my local dealer and he said it was the voltage regulator because he had seen the same problem with other bikes. He said if you turn the high headlights on it would work fine. Thats the same identicle thing mine will do. The stupid parts dealer said the cost was 125.99 for the regulator and he would have to order it. I will do the tests first just to make sure 125 is a hunk of change. I'll keep you guys posted...

 

Crap ya i see that, it was 111 canadian... now its over 200. Heh, wonder if you can still get this part number from AC 3430-016 this is the orig one. 111 canadian, bout 75 US id guess. Lets hope its not that. Check the connections back at the regulator if you havent already. Heres the harness so you can see where it is.


http://www.brownsleisureworld.com/Parts/ATV/1998/1998ATV4544x4(98A4A-1998)/WIRINGHARNESSASSEMBLY.htm

Good luck and keep us posted.

 

OUCH!! THe first time I checked alpha-sports it was right at $100 US with shipping. Now it's $135 + shipping. So your dealer has the better price.

Voodoo, I bet the new unit is the same thing as the old unit just change the # and get more $$$$$$$. I had one go out on an old Kawi 300 and the dealer had one on the shelf for over 5 years but it still wanted to charge me like it was the new unit. (reason for the # change was new manufacture) So I told him he could order me the new one and keep the old on the shelf. He told me I could go elsewhere, so I did.

 

Well they have a new part number. The original Reg is 110 Canadian, and the New one is 200 Canadian. Hmm your right i think.

 

Well it turns out it was the voltage regulator. It started acting up today and I decided to test how much voltage it was putting out at the battery while it was acting up. It puts out 19.79 volts when it is messed up and 14.7 when it's ok. I then disconnected the voltage regulator while it wouldn't run right and it cleared up and ran perfect. Plugged the regulator back up and it started acting up again. I am going to try to get the dealer to cut me a deal on the part. I was thinking maby they discontinued the older part and the new part number is a replacement for the faulty one. If it is the same identical thing with a new number to make more money then screw them for being that way when a man is in need!

 

Glad you found the issue. Hope it doesnt cost to much :/

 

I went to the dealer today and ordered the part. He acknowledged that the change in part number and price was prob for more money or just new pricing. I told him to hook me up with a discount and he said he would let me have it for 100 bucks out the door and it will be in friday. They told me they will be getting the new cats in October. They will get around 6 this year and ever how many they want next year.