First off GREAT SITE...
Bought a basket project and now 95% together and looking great- fresh rebuild engine and front dif. this is my first large 4x4 ATV, have all manuals too, Great learning experience.
I finally put in new battery - all electrial works as it should.
However no spark-
I have read about old ignition designs and a $500.00 upgrade - cant do that rt. now.
So I will try to find problem, this machine had AND MAY STILL HAVE broken wires.
Can you tell me about the circuit breakers in the sealed pouches - there is 1 for ignition? if that were bad would that cause no spark?
I have not opened it up yet or done a continuity test.
My first thing is I opened up the harness below headlite to check all wires.
Next is to start testing as listed in service manual.

Can someone give me a better place to start?
I know it can be a few items (startor,p/u, coil, cdi,ground,bad wire).

This thing cranks perfect- just no spark.
Guess I need some specail volt meter too?
How can you tell by just VIN number when it was made- no sticker in fender for date of mfg.
I know its late 2004 due to the front diff. design, and transmission.

Sorry for long post - but trying to give much info...
Thanks

 

The 10th digit is the year code. 2004 would be a 4. ATV Vin Number : Check and Decode Your VIN

 

Yep got that one- however I have seen people talk about mfg. dates, and when you order parts I see it asked sometimes - just curious..
thanks

 

Just pop the front panel and see if it has a combination cdi/coil pack with the words Ducati on it. If it does don't bother trying to find out why it doesn't have spark.Don't buy any used or new Ducati parts! Just save up and buy the replacement Kokusan kit.Check Bike Bandit,Cycle Parts Warehouse,Cheap Cycle Parts,etc as to the best price.Plenty of people on the forum have had to change their ignition out and I did more than I want to remember.Here's the pdf kit parts/instruction manual. http://www.google.com/url?sa=t&rct=j...60799247,d.aWc

 

I know the coil is all by itself what I am used to seeing on other atv's. there is a black box screwed to the panel that has a large jack going to it. I know 2 wires plug into coil and the black one goes to what I thought was the CDI.
So I assume since its a 2004.5 it is not the older version you spoke of?

thanks

 

Yes if you have a separate cdi and coil,then you do have the later system. On electrical checks best to have a service manual and schematic that shows resistance readings on the stator,coil and other areas to check. Could be as simple as trash/dirt around the pulse coil on the stator.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Plus here's a free pdf on a 2005 mv700 that is basically the same as yours that shows the resistance checks on the 2nd page of the schematic.http://gh-ftp.com/ORV%20Manuals/Pola...m%20-%20SM.pdf

 

GREAT NEWS what a relief that I have the newer system- thought so
I had the complete engine apart it cam e to me with bad rod bearing- totally rebuilt engine and clean like new stator and all. However when i got it the 9 wires were cut so I put on an 8 pin jack and the brown by itself since heavier gauge.
I plan today to start testing OHMS using the manual and wire diagram.
First do you think I should test circuit breakers- is there one that runs spark?

Thanks alot OPT I have read many of your posts.

Will update my findings later today..

 

Depending on the build date the circuit breaker is in a sealed pouch up from the battery. If you have a black finned module under the front panel that's one of the early ecm modules that have the circuit breakers,charging built in and they can cause problems. Check first on the ground wire(s)you mentioned as it could be the source of no spark if not grounded properly.

 

OPT- Thanks Here are some findings rather long but alot of information:
CDI is mounted to the front panel no fins..Ground wires all ok even took off and redid and cleaned.
All brown wires in large connector getting good ground contact.
(2) circuit breakers are ok ( used meter and it beeps when I touch each wire with meter leads - so closed circuit)
Stator readings:
orange to white=.7
yellow to grd=open
blue to green=182
blue to grd=open
orange to grd=open
Question yellow/red I am confused - schematic says I should have yellow/red & yellow brn. I don't, mine are (2) yellow/reds and a single yellow. I think this is for charging and not sure if needed to investigate for no spark.
Remember the main harness from stator was cut so I put back together with 8pin jack.

Here is where I am a little confused.
Coil readings:
I disconnected the black and white wires from CDI
touch blk with one meter lead and white with the other- it beeps -closed circuirt. Same thing if I touch the white wire and black wires on the CDI it beeps. IS THIS SUPPOSED TO BE?
Neither the black or the white on the coil give me a reading when I put to ground (open).
High tension (spark plug wires)
Tester in each here are the readings (not sure how to properly read)
set @20K=14.39
200K=14.3
2000K=013
I think these are in spec.

SORRY for long post..

 

FYI..
I have pics on my album- and can add more if it helps.
Thanks