I was riding my 450R across the dunes saturday and it just died. I have no spark from the plug or the coil. I do have 1 wire on the cdi box that gets power when I kick the motor over, and also power going through the ignition switch and the kill switch. I thought possibly the cdi box was bad so i tried the cdi box off of my friends 04 but mine is an 05 and i'm not 100% sure they are the same but it didn't work all the same. Although I have power going to the cdi box, I have no ignition pulse to the coil. Does anyone have any suggestions on what the problem might be or does anyone have a wiring diagram I can go by? I have been an auto mechanic for 15 years and i'm very good with electrical systems, but I don't have any experience with this system and how the power flows to and from the pick up coil on the crank. Anyone????????

 

come on, somebody must know something or at least have a wiring diagram.

 

This is the same problem I have on my 03 400. Today I checked to see if I'm getting any voltage from the mag when I turn over the starter, but nothing. ( not sure if that is right or not) I do get 12v to the coil, kill swith and safty neutral ground switch both good, but no spark. If you should locate a wiring diagram please send it to me. I'll do the same. If I solve the problem I'll let you know.
thanks

 

the 03 400 and my 05 450 will have some different wiring because my 450 don't have a battery or electric start. If you have power going to your coil, it should pulse when you crank the motor over.

 

Will a bad voltage regulator kill my spark?

 

All these 450R's out there, and nobody knows anything?

 

Here i took a digi photo of my wiring dia. hoipe it helps

http://webpages.charter.net/white7/dia%20002.jpg

 

Weak or no spark checks

1) faulty spark plug
2) Fouled spark plug
3) loose or disconnected ignition system wires
4) Broken or shorted Plug wire
5) faulty ignition coil
6) faulty exciter coil
7) faulty ignition pulse generator
8) Faulty engine stop switch
9) faulty ignition switch
10) faulty ignition control module (ICM)

 

I had this problem with my big red. Rode fine, parked it then no spark. all it was the coil had come loose inside at the elbow. Re- crimped the wire to the tip that sits on the plug, and it s fine now.

Try taking apart the coil and put it back together.

You could also check the grounds all over the engine. you need strong connections everywhere to get good spark.

my money is on the coil, they're known to come apart on all wheelers. Good luck man!

 

Anyone know how to test the exiter coils? I think that is my problem, but i'm not sure how to test them.