Quote:
Originally Posted by Joe454
hi everyone new here to the forum.. have to say this quad has exhausted me to no end..
no spark issue...1. went through the complete harness 2. tested check coil test fine.. 3. test stater /pulsar coil. test fine..4 removed flywheel inspect the magnet area.. sealed! impregnated plastic with inner steel ring overmagnets.
pulsar pick up working recieving 4.5 volts.. stater 0 a/c voltage at rectifier wires and 0 a/c voltage going to cdi box. "ac voltage only" has good grounds cdi box 3 wire splitter, at the coil. and even ran an extra ground from coil bolt to ground for battery bolt on side cover right side of engine.
plug is at 4.5 ohms
stater 3 wires .2 ohms.. all 3 wires test to ground no continuity
stater a/c volt input wires .2 ohms
stater pulsar coil 213 ohms
also checked key switch,stop switch front rear brake switchs hd switch hi lo beam switch and fan switch.witch needs replaced its bypassed with a toggle switch.per other owner.
bought a used stater tested the same as mine in the quad.. replaced fly wheel
problem still excites no a/c voltage coming out of stater at all.
tested for spark with a dirtbike plug i had laying around test ohms at 4.09 show very min..spark but present.?????
CDi box was the next purchase or even bying a newer style connector say out of a 03 04 and repin my harness to the new style cdi box.. way cheaper to do..any thoughts?? please help
|
Hello;
I have run into this problem before,since you have checked most of the electrical components,maybe this could be your problem.First you said you checked the flywheel magnets did you try to move any of the magnets,sometimes when they come loose they move around and look normal.If that is ok.Lets check one of the most common problems with this machine I have 3 of them one 500 and 2 454's and I'am an old motorcycle mechanic for 40 years.Check the plug where your voltage regulator plugs into on the wiring harness unplug it.It's the red wire on the top right side of the plug it's heavier than the other wires.The connector on this wire sometimes goes bad from the heat of the regulator and getting dirty and wet.You should splice back a couple of inches of the wrapping to make sure it has not melted into any of the other wires.You want to look at all the wires and connectors going to the plug.Sometimes the red wire melts into the other wires.I usually splice back 3 inches to see,if you see any melted together just make a splice to repair them and solder the wires.This RED wire supplies you 12 power to the rest of the system and when it is pluged into your regulator completes the circiut that supplies spark to you spark plug.Besides this there are many electrical problem with this machine,the stator is the main problem if the trigger coils are bad you won't get any spark and sometimes they test good with an ohms meter.Good luck.
Ron