Hey Silver Bullet,

I just re-read your post. Again I'm confused, Looking at the parts diagram, I only see an "Ignition Controller", I don't see a CDI box or a coil? Can you explain more? Thank you.


Chip.

 

No , what I mean is , the current of a spark through one sparkplug also depends on the other sparkplug lead being connected to a plug or grounded out to the engine block , ........ this is because in this coil design , the secondary part of the coil is " not " internally grounded within the coil , ....... but rather the ground is esentually connected to a second spark plug wire within the coil , .......... so in order to complete the current path this coil design has to jump 2 spark plugs to make the cuurent path !

So , if you have a spark at all , there can be nothing wrong with your ignition module

 

In other words you , not understanding it works this way , it's easy to fall into a trap of pulling one lead off , checking for spark in that lead , all looks good , then pulling the 2nd lead off , but not reconnecting the first , then checking the second lead and finding there's no spark on that 2nd lead and assume there's a problem with spark at that lead !!!!

Iv'e seen this scenario confuse more than a few people in the past

 

Hi LenTech,

OK, now I understand what your saying. No, I did not check the spark plugs with the other side disconnected. What I did was I checked each side by watching for the spark as well as using a spark test light. And, I did the test with 3 different brand new spark plugs. Still no spark to the one side.

As I stated earlier, I did replace the Ignition Controller.

What would you recommend that I do next?

Thank you for your assistance!

Chip

 

if you have confirmed spark at one side but not the other based on the method previously described , then check the coil wire on the side there is no spark on , ........try switching left to right ,.......... still none , ......get yourself another coil , it's shorting inside to ground

Hope this Helps you

Len....

 

Had the exact prob with my buddys' 700. It ended up being the plug wire, just resting on the coil (not "snapped" in place). We couldn't figure out how it could have come off, due to the tight clearance with the splash guard that the coil is mounted on.

It was a bitch to get back on, and he had to put some dielectric grease in the boot to keep it from arcing. (never fit as tight as on my 800)

Been fine since.

Coils very rarely fail, contrary to popular belief. The chances of a new coil failing are even slimmer. Problems attributed to the coil usually end up being something elsewhere within the ignition system--Wiring 98% of the time.

 

OK, tomorrow morning I'll check to see if the plug wire is connected tight into the Ignition Controller. But I agree that the odds of the same wire being loose on the original Ignition Controller and the replacement are very rare.

I guess after that I'll look again to see if I can find any bad wires anywhere else. I couldn't find any before, that's why we thought the controller was the problem in the first place.

If anyone can come up with any other ideas, I would greatly appreciate it. Thanks.

Chip