Hey everyone!

I am new to the boards and hope that someone can help me out. I have an 03 Scrambler that I have rebuilt. It was a project but was running before. I had a good friend/motorcycle mechanic come by, and we found that I am only getting on spark and then nothing!

Has anyone out there heard of this problem? Is it my CDI? I have swapped out the coil and that didn't do it.

Thanks for the help!

 

If you didn't replace the pulse coil make sure you have around 97 ohms resistance between the white and white/red wire. Also check that the pulse coil to flywheel gap should be between .016 to .040 according to the manual. You can also pull the black wire (kill wire) from the cdi and see if you have strong spark. Also remove the black wire from the limiter module and see if spark is better. Item #31.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Plus here's what one member found was his problem on the pulse coil:
"I really had my wits tested on this one, and it had me going in circles only to wind back up at the pulse coil (trigger). I was thinking, I had spark only when using the recoil, so what's up with that? I asked my self, one last time and if I couldn't figure it out, then I'll throw in the white flag, which is something I'm not doing without a fight

I remover the recoil cover last night after work, and began inspecting...

I looked at the pulse coil for any signs of rust, damage ect...nothing except for a large gap between the coil and flywheel magnet, I thought that looks incorrect, thinking back on all my years working on cars and small engines.

Well a while back the pull rope broke while engine was running. The cord wrapped around everything under the recoil housing and caused the starter bendix to jamb. I found frayed cord all over the place and bits of metal stuck to the magnet on the pulse trigger. I cleaned all this up and installed a new starter bindix, buttoned everything up, and that's when this no starting issue came up...well to shorten this up, apparently when the pull rope broke cord jamed everything up inside the recoil housing, it also pulled (bent) the pulse trigger down away from the flywheel magnet. In this position the trigger was only able to send the electrical pulse to the cdi to fire the coil, when using recoil starter, because it rotates the engine at a slower speed, than the electric starter, so the pulse coil could pick up that slower magnet of the flywheel and not the faster moving electric starter because of the large air gap, resulting in a no start when using electric starter, condition

feel free to correct me if I'm incorrect,

but when I bent the pulse trigger back up in the correct position and reset the air gap, re tightened the screws, installed the recoil housing. I went to check for spark at the plug with electric starter.....GOT BIG BLUE SPARK!!!!!!! now lets put the plug back in and see if she will fire up.....YES! YES! YES!!!! it fired up on the first hit of the key..
the end

 

Thanks so much for the response! My friend is coming by tonight to help again and I'm going to show him this. I did pull off the cover and the rope was there but a little frayed, and there was a ton of debris in there that almost looked like road salt! I cleaned everything but haven't tried starting it...but will later on tonight!

Is there anything you think I should jump on and overnite myself in case this doesn't solve the problem?

Thanks again!

 

Make sure you clean the pulse coil face good. When you clean it all up inside, silicon the rope handle over the rope hole so water never gets in there again.
A small hose clamp around the pull rope handle is extra insurance.

 

Just clean the stator area up(face of the pulser coil and around the flywheel) and see if the pulse coil needs adjustment,plus look at puling the black wires I mentioned if this doesn't help.Plus if the pulser coil is not new it should show 97 ohms resistance between the White and White/red wires.