Hi everyone:

I have a Redact trail 70 that I recently upgraded to an 110cc Kazuma replacement engine. Before I replaced the engine, I had some intermittent stalling problems that usually resulted in just starting the bike back up and no problems before I replaced the engine. After a summer of this the problem graduated up to the engine not cranking over and having to be kick started. Assuming the battery might be past its prime, I replaced it with a new unit. This did not work. This is a 4 wire CDI system with the two shoe type stator assembly.

I replaced the engine, and while doing so ran into another problem. Very weak spark on cranking and if the engine started at all, it ran for a minute or so and died not to start again. Let it sit a couple hours, it might start, it might not. At this point, I left nothing to chance because getting specifications for testing the CDI unit and Stator assembly just don?t exist (at least I can?t find them).

The new 110 cc engine had a "star" shaped stator assembly that was clearly for a 5 wire CDI. I had to swap out the stator cover, stator assembly, and flywheel to the new 110 CC engine to make it all compatible with the Trail 70 wiring harness. I also swapped out the ignition coil with a known good one, and the rectifier and adjusted the valve lash and checked closely for vacuum leaks and cracked intake manifold just to eliminate the obvious.

I replaced the CDI, the stator and still no relief. I than dis assembled the kill switch on the throttle handle and bypassed it and VOLA! It started and ran GREAT! Problem is, now I am right back to my original problem. IT seems like the ignition system is running on the battery as the bike will run for about a half hour, quit and the battery will be dead. I charge it up, and it runs great for about a half hour and dies again. ARGGGGGGGGGGGG!

I am getting less than 12 volts at the battery when the engine is started, and if I shut off all the lights get just a touch over 12 volts at the battery. Not enough to keep it charged it would appear.

I have a few questions for all of you who might feel so inclined to offer your opinions as to what I might want to look for before setting this thing on fire:

1) What in the h*ll am I missing here? I ordered a new throttle handle kill switch but even after bypassing the original, the problem is still here. I have a new one on the way, but I really don?t think this is the problem after bypassing it.

2) There is a one wire sensor under the drive gear cover that I can only assume is a crank position sensor, am I correct on this?

3) Anyone know where to find some REAL specifications for the electronics for these parts? Stuff like coil impedance for the stator and ignition coil and pin identification on the CDI, Rectifier and signal info. On the crank trigger?

5) Anyone know a reliable load testing method for these dry cell batteries? I can?t find a cranking amp specification to save my life here.

I know a lot of stuff has been worked on here folks, but If I can find some good specifications, I might become an expert on these ignition systems on these Kazuma products. It?s pretty tough to diagnose problems when none of the wiring diagrams in the owner?s manual match the bike and no real specifications are available in the line of coil and stator impedance or CDI pin ID.