#0 The ATV had been running but stalled so I got to do this test, and it made no difference... it would not start.

#1. How many ohms - .3 ohms
Variation - none

#2. How many ohms w/kill switch in run position - infinite
In off position - .3 ohms
no variation when flexed

#3. The white/blue wire shows continuity to the coil (from CDI)
.4 ohms across the coil (black/white to white blue)
infinite ohms from CDI white/blue wire on harness side to ground
no variation when flexed

#4. N.A.
#5. forget for now
#6. forget for now

#7. I just don't understand this test at all. Can you explain it like I was 3? LOL!


Today, I once again took the ignition switch apart and cleaned it. Then, I jumped the wires ahead of the switch via the connector when the bike was in a no start mode, and it still wouldn't start. I just used a length of wire and stuffed it into the orange and red wire slots. The quad turned over, but stil wouldn't fire up.

Then, feeling courageous, I proceeded to take the kill switch apart. That wasn't so easy since it had the start button, choke and light switch wires involved. I managed to get it apart and cleaned all the contacts inside that too. After several attempts to get it back together properly, I finally succeeded and the ATV started right up. It kept running and starting over and over time after time. Again, I thought I had it. But no, it stalled then wouldn't fire again. GGGGRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRRR!!!!! !!!!!!

Next????? Do you still think it is in the ignition switch?

Jackie

 

#3. infinite ohms from CDI white/blue wire on harness side to ground

This reading should be a few ohms. Either the test was not done correctly (the only connector that should be disconnected is W/BL at CDI) or you have found your problem...

Do you still think it is in the ignition switch?

I never thought it was the ignition switch.

Jackie[/quote]

 

I shall do that portion of the test again tomorrow. I hope I still have the same results, then we'll have the answer to this mess!

PLEEEEEEEEEZE... keep your fingers crossed, okay Ken?????

Thanks again for your help!
Jackie

 

I did #3 correctly this time and got a reading of .6 - .7. It kept changing and I haven't a clue why. Seems my tester is a little wonky. Several times now I have gotten readings that start at.. say 1.8 then drop down to .3 to .5, then keeps varying between .3 and .5 . That can't be right, can it? It's a brand new meter (Crapsman model 82139)

I tried doing #7 of the test tonight, and found something interesting. There is a waterproof connector at the magneto with a green/white and a B/Y wire going in and a green and a black wire coming out of the connector. I was opening the connector for testing purposes and upon closing it, I saw that one of the male parts of the plug was much lower then the other. I grabbed a pair of needle nose pliers and pulled it back to it's correct length. I tried to plug the connectors halves together and I could feel the wire being pushed out of the back of the conncetor. So, I got a small screw driver and held the
connector in the proper position so it would engage completely. The wire in question is the green/white to green after the magneto. Could this be part of the problem? Since I got this connection fully engaged the ATV has been starting fine... BUT.. this has happened before.

Yesterday I checked the spark several times and got a thin orange colored spark. I now have a wide orange spark. Shouldn't the spark be bluish?

Thanks :-)
Jackie

 

I think you've done it! That G/Y wire comes from your pickup coil, which tells the CDI when to fire. So that makes perfect sense.

 

Well Ken, I surely hope so. I cannot tell you the hours I have spent trying to find the problem. You have spent time on this, as well, and I cannot thank you enough. It was your testing that sent me to the area which revealed the bad connector. Let's just hope it does the trick and keeps this ATV running. I would love to get it back together before it gets much colder.

If I still have trouble, I will be here looking for YOU! LOL!

Keep your fingers crossed, and thanks again!
Jackie

 

Well, I just got my Clymer yesterday so I have more tests if needed

But, I think you'll be fine, although....

You may want to take that ignition switch apart one more time just to be sure

Anyhoo, Happy Trails
Ken

 

It's possessed! It has to be! It has been running and starting perfectly so I decided to put it back together today while I had the time. I kept starting it every step of the way, and it never let me down. Once I got it completely together, I drove it around the property and was a happy little camper. I had a phone call and was in the house approximately an hour. I went out to put the ATV away and guess what??????????

Ya know, I have just about had it with this piece of junk. If I had a dollar for every hour I have spent working on it, surfing the web for information, or just plain thinking about it, I could buy a brand new one.

THE DAMN THING IS POSSESSED, and YES I am SCREAMING!!!!!!
Jackie

 

Just got back from Bar Harbor, did you make any headway?

 

I certainly did..... I bought a gallon of gas and a pack of matches!!!!!

You have some nerve taking off to Bar Harbor when I'm having a Zuki Roast! hahahaha!!

Now, on a serious note. I cannot find a thing wrong, and decided there just may be something to this ignition switch that others have mentioned. In fact, I had a long conversation with a dealer (NOT the SOB that ripped me off), and he said the older Suzuki's did have an ignition switch problem. So, I ordered the switch from him and it should be in tomorrow. The price was the same as I found online by the time I paid the shipping... less the tax.

I'll let you know how that works out, but personally, I don't have much hope.
Are you studying that Clymer book????? Got any new tests? I just may need them!

Jackie