I am working on 2006 Honda trx350 rancher for a friend. I am having a problem with it not sparking. I have been through the trouble shooting in the manual and searched online for any other info to check. So far this is what I have done:
1. Checked the kill switch which was good
2. Check all connections they were all good
3. Checked the pulse generator with a peak voltage adaptor on a multimeter and the voltage it was cranking was around 5 volts and the manual said the minimum was .7. So I don't know if that is too high or not.
4. Checked the charging system just to make sure by checking continuity. It all checked out.
5. Checked the gear position switch. It was also good.
6. Got a new spark plug along with a new ignition coil.
7. Then I checked the voltage going to the ignition coil. This is where it kinda gets weird. So when the ignition coil is plugged in there is only about .04 volts going through the black yellow wire when the engine is cranking over. But if I unplug the coil and just put the multi meter into the the wire it reads 120 volts constantly.
So after checking all these things it is still not sparking. I have a spark tester that I am using and also just touching the spark plug into the cylinder. But when I have my spark tester all hooked up when I turn it on the tester flashes but doesn't do anything else. The only thing I can think this would be is the ICM (cdi). But there is no way to test it that I know of other then getting one that works. And I know no one that has one that I could borrow to swap in. Does this sound like this could be the problem, or is there something I'm missing?

 

How olds the battery? I can't explain why but I have seen some strange issues more then I can count on the Honda when the battery cranks over fine and test fine. Replaced the battery and gremlins went away!

 

Put in a new battery not too long ago to make sure that wasn't it. Sorry forgot to say that. But yea I understand that, I've done the same thing.

 

Have you checked to make sure you have a good grounds.

 

Maybe do all the ohm tests on that new ignition coil, sounds like it may be shorting in some way. New parts aren't always good, unfortunately.

Was the old ignition coil tested?

 

I'm in the same boat and have no spark. I am only getting 1.6 volts to my coil. Any advice as to where to go from here?

 

If you have done all the ignition circuit tests in the workshop manual and everything checks out as right, this leaves the CDI, which is unobtainable. However Honda do a work around using a different CDI and a bit of extra wiring loom to adapt it to fit the existing loom. This is expensive, so be very sure you have checked everything else out properly first.

 

Voltage regulator

 

Yes, try for a spark with the voltage regulator disconnected, wouldn't fancy running it like that, but have found on 450s that disconnection fetches spark back if the regulator is the problem.