04 Sportsman 700 twin NO spark
Hey everyone, I am a new member to the site but not a stranger. I have used this site and others in the past for help and research when I was rebuilding my 97 Sport 400. Now I acquired an 04 sportsman 700 twin for REALLY cheap and I am having a hell of a time trying to get it to run. I will provide all the info I can on what I have found and done so far.
As the title says, I have no spark at all. This all started because I purchased this from my uncles neighbor who hadn't used it in 3 years. It sat on his farm out in the elements the whole time. Battery was dead and it would not fire up. He connected a jump box to it to show me it would not fire up and I still purchased it from him (smart move, right?). He still had the same fuel in it from 3 years ago. So I figured it just needed a battery, carb clean and new fuel.
I have been doing some reading and it looks like the ducati ignition system was a problem with these. But mine has the newer kokusan ignition on it. This ATV is the later 2004 model. My coil is separate from the CDI module. I don't have a way of testing the CDI module but I spoke to a tech at a motorsports dealer in town and he said "it is very rare that these CDI's go out so there must be something else going on." He could be wrong on that though and I am hoping he isn't because that thing runs around $250 and if I order it I am stuck with it since they do not take back electrical components. Any help would be appreciated on this. Sorry if I lost you I know it's a long post. Hoping maybe OPT gets a look at this one, he seems to be very good at this problem solving. Just want to get this thing running so I can enjoy the trails this summer. |
According to the specs you give, the stator ignition section looks within range especially the trigger coil, only the Yellows which are for the charging shows to be slightly out.All resistance specs are + or- 20% which shows you have some wiggle room on the readings..I agree that if you if you can't find a bad ground(I'd check the main ground also on the stator plate) then its possible you could have a faulty cdi module.Kokusan ignitions are very reliable,but any ignition system can have problems.
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Thanks OPT, I will check the main ground also. That is probably the only ground I didn't check. Since it is mounted to the engine I assumed it was already grounded.
Would the Voltage regulator cause any of this problem? I did have the front cover off a couple of days when it rained here and it got wet but the battery was disconnected. Everything was completely dry again when I got back to working on it and plugged it back in days later. I wouldn't think water should be an issue since ATV's are meant to go through water and mud. How would I test the voltage regulator if needed? |
Having the front cover off wouldn't help matters any with water pouring in. Just blow out all connections to make sure,use electrical grease on connections if you have it.Check the stator ground and all other ground points on the frame. Old rule of thumb on checking regulators is that there should be resistance between each wire,no shorts. Just see if cleaning the electrical up helps and it you get it running make sure you're charging 14 volts back to the battery.
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Thanks a ton. I will Get working on it later today and update you on what I find
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I guess I never updated this...
It was a bad CDI module in the end. |
Glad you found the problem. That's why the manual has specs for the stator,pick up coil and ignition coil among other electrical trouble shooting checks.You eliminate these as the cause and narrow it down to the cdi and the manual says to replace the cdi "with a known good one" No specific tests shown for it.
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Thr
Originally Posted by BROCK2969
(Post 3189819)
Hey everyone, I am a new member to the site but not a stranger. I have used this site and others in the past for help and research when I was rebuilding my 97 Sport 400. Now I acquired an 04 sportsman 700 twin for REALLY cheap and I am having a hell of a time trying to get it to run. I will provide all the info I can on what I have found and done so far.
As the title says, I have no spark at all. This all started because I purchased this from my uncles neighbor who hadn't used it in 3 years. It sat on his farm out in the elements the whole time. Battery was dead and it would not fire up. He connected a jump box to it to show me it would not fire up and I still purchased it from him (smart move, right?). He still had the same fuel in it from 3 years ago. So I figured it just needed a battery, carb clean and new fuel.
I have been doing some reading and it looks like the ducati ignition system was a problem with these. But mine has the newer kokusan ignition on it. This ATV is the later 2004 model. My coil is separate from the CDI module. I don't have a way of testing the CDI module but I spoke to a tech at a motorsports dealer in town and he said "it is very rare that these CDI's go out so there must be something else going on." He could be wrong on that though and I am hoping he isn't because that thing runs around $250 and if I order it I am stuck with it since they do not take back electrical components. Any help would be appreciated on this. Sorry if I lost you I know it's a long post. Hoping maybe OPT gets a look at this one, he seems to be very good at this problem solving. Just want to get this thing running so I can enjoy the trails this summer. |
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